RU2642079C2 - Dry potato puree production line - Google Patents

Abstract

FIELD: food industry.

SUBSTANCE: invention relates to food industry, in particular, to complex processing of potato raw material. The line comprises a self-propelled conveyor with a weigher, an accumulation bin, a washing machine, an inspection conveyor, a steam cleaning unit, a drum cleaning machine, an inspection belt, a steaming plant, a cooler, a cooker, a potato masher, a cylinder dryer, a collection bin with magnetic catchers, a weighing-and-packing machine. Two screw conveyors with a brushing machine in-between are installed in the line after the steam cleaning unit. A hydrocutting machine is mounted after the drum cleaning machine with the inspection belt. A rotary mill with a separator for particle fractioning is placed after the cylinder dryer. The line is additionally equipped by a waste processing section comprising waste collection bins, a press for preliminary mechanical dehydration of starch-containing raw material, an accumulation tank, a belt convective dryer with a regulation doser, the accumulation bin with magnetic catchers and the weighing-and-packing machine.

EFFECT: invention implementation allows for the improvement of the finished product quality.

1 dwg

Description

The invention relates to the food industry, in particular, to the integrated processing of potato raw materials and can be used for the production of dry mashed potatoes with the processing of potato waste in the form of a feed product.

Known technological line for the production of dry mashed potatoes [Katz Z.A. Production of dried vegetables, potatoes and fruits. - 2nd ed., Revised. and add. - M .: Light and food industry, 1984. - 216 p.]. The line for the production of dry mashed potatoes in the form of flakes is characterized in that it contains a hydraulic conveyor, automatic scales, a drum washer, inspection conveyors, a calibration machine, a potato peeler, a post-treatment conveyor with a drum washing and peeling machine, a potato slicer shaking machine, sulphitator, blanching machine, hopper cooler, cooker, screw potato planter, single-drum dryer, conveyor grinder chitel, flocculator, magnetic separators and Packaging and packaging equipment.

The disadvantages of the production line for the production of dry mashed potatoes are the presence of unused waste that contributes to environmental pollution, low environmental safety of production, and the need to use a washing and shaking machine to wash starch and small particles from the surface of the cut product and ensure the required quality of the finished product.

The closest in technical essence and the achieved effect is the technological line for the production of dry mashed potatoes [Serpova OS, Borchenkova L.A. Resource-saving technologies for processing potatoes: Scientific. an. overview. - M.: Federal State Institution "Rosinformagroteh", 2009. - p. 37], which provides for three sections: the first is the preparation of potatoes from washing to cooking, the second is the preparation of mashed potatoes for drying, the third is the drying of prepared mashed potatoes. The line includes a land-cleaning machine, a washer, an inspection conveyor, a conveyor belt, a steam cleaning unit, a dry cleaning unit, a washing and cleaning machine, a potato cutting machine, a starch washing unit, a blanching machine, a cooler, a cooker, a potato washer, a single-drum dryer,

The known production line for the production of dry mashed potatoes has the following disadvantages: low quality of the finished product, which is associated with low organoleptic characteristics and a large loss of nutritional value of the finished product due to contact with atmospheric oxygen and oxidation of substances, high energy consumption during production, the use of equipment for additional washing starch. Moreover, the process of preparing potatoes from washing to cooking is carried out according to the same technological scheme and in the same modes [Katz Z.A. Production of dried vegetables, potatoes and fruits. - 2nd ed., Revised. and add. - M .: Light and food industry, 1984. - 216 p .; Serpova O.S., Borchenkova L.A. Resource-saving technologies for processing potatoes: Scientific. an. overview. - M .: Federal State Budgetary Institution “Rosinformagrotech”, 2009. - 84 pp.]: Washing, inspection, cleaning, sulfitation, cutting, washing, inspection, blanching, cooling, cooking. However, the well-known line for the production of dry mashed potatoes also contributes to the darkening of the product, reduction of the organoleptic characteristics of the finished product, requires the stage of sulfitation, the use of 0.1% sodium bisulfate solution and the use of sulfite to preserve the color of the potato.

The technical task of the invention is improving the quality of finished products, reducing energy costs during production, the intensification of technological processes, reducing the cost of the main production due to the additional, waste-free production of dry mashed potatoes.

The object of the invention is achieved by the fact that in the production line of dry mashed potatoes containing a conveyor with scales, a storage hopper, a washing machine, an inspection conveyor, a steam cleaning unit, a drum washing and cleaning machine, an inspection conveyor, a blanching machine, a cooler, a cooker , a potato masher, a roller dryer, a hopper collector with magnetic catchers, a filling and packaging machine, the new one is that the line contains two screw units after the steam cleaning unit a conveyor, between which a brushing machine is installed, after the drum washing and cleaning machine with an inspection conveyor, a hydraulic cutting machine is located, and after the roller dryer there is a rotor-type mill with a separator for fractionating particles, while the line additionally provides a waste processing section, including storage bins for waste, press for preliminary mechanical dehydration of starch-containing raw materials, storage tank, convection belt dryer with adjusting capacity ozator, silo hopper with magnetic catchers and filling and packaging machine.

The technical result of the invention is to improve the quality of finished products, reduce energy consumption during production, wasteless production of dry mashed potatoes, reduce the cost of production of the main products due to the implementation of additional, as well as improve the environment and environmental safety of plants during processing of potatoes due to the maximum utilization of potato waste .

In FIG. 1 shows a general view of the line for the production of dry mashed potatoes.

The technological line for the production of dry mashed potatoes (Fig. 1) contains a conveyor with weights 1, a storage bin 2, a washer 3, an inspection conveyor 4, a steam cleaning unit 5, screw conveyors 6, a brush machine 7, a drum washing and cleaning machine 8 , water-cutting machine 9, inspection conveyor 10, blancher 11, cooler 12, cooker 13, screw potato masher 14, metering devices 15, roller dryer 16, hopper-chopper 17, rotary mill 18, hopper-collector 19, magnetic traps 20 and a filling and packing machine 21. The waste processing section includes storage bins 22, a press 23 for preliminary mechanical dehydration of starch-containing raw materials, a storage tank 24, a convection belt dryer 25 with an adjusting batcher, a storage hopper 26 with magnetic traps, and a packaging and packing machine 27.

The production line of dry mashed potatoes works as follows (figure 1).

Raw potatoes are transported with an automatic weighing machine 1 to the storage hopper 2. Then the potatoes are fed to the washer 3. They are washed with tap water until all contaminants are removed, the ratio of water to tubers is 3: 1. The washer has a manual hydraulic control valve, which is installed at the end of the washer drum, to adjust the level of filling and the quality of washing. The washer also has a scraper mechanism for removing floating elements, installed after the drum. With the help of the water circulation system, the residence time of the product in the drum is regulated and, thus, the amount of water added from the outside is reduced. The clean water irrigation system on the discharge conveyor belt further rinses the product and removes any remaining dirt, if any. The drum is suspended on a tape structure, and all rotating parts are above the water.

Washed potatoes are inspected on conveyor 4, discarding substandard, rotten and damaged tubers. Next, the potatoes enter the steam cleaning machine 5, where it is preheated to prepare for further cleaning. The product is treated with steam at a pressure of 0.40 ... 0.50 MPa for 15-60 s. Due to this vapor pressure, water under the skin of the product boils and lifts it. Then the pressure drops sharply, the peel “sags” on the surface of the tubers and is easily removed, helping to remove the skin from the surface of the tubers. During the processing of potatoes, starch thickens.

 After the steam cleaning machine, the potatoes are fed into the brush machine 7 by means of a screw conveyor 6, in which the peel is completely removed. The machine has 2 frames with brushes. One frame is fixed, and the second moves in the horizontal direction. The machine is mounted on the chassis with stainless steel castors. Each brush assembly is driven by a motor via a belt drive. The brush shafts are fixed in reinforced spherical roller bearings with additional protection against water ingress. Two channels on the sides of each frame with brushes collect cleaning. The space for the product between the brushes can be changed; this is achieved by removing the side sheets. The distance between the two halves of the machine can be manually adjusted horizontally using spindles for tuber crops of various sizes, maintenance and cleaning of the machine.

 Then, using the second screw conveyor 6, the potatoes enter the drum washing and cleaning machine 8. The residence time of the product in the drum can be controlled using a slide valve at the end of the drum. The additional cleaning process is carried out during rotation of the drum with the help of spray hoses inside the drum and due to friction of the product. Waste constantly flows to the bottom of the machine through a perforation or drum plate.

After additional washing and peeling, the potatoes arrive on the inspection conveyor 9, on which the peeled potatoes are inspected and substandard tubers are removed.

The peeled potato tubers are fed to a water-cutting machine 10. In this machine, potatoes moved by hydroflow are cut into plates and washed with cold water in order to remove starch grains without contacting the oxygen in the surrounding air. The hydraulic cutting method is based on a balanced pump product supply system with a compatible equalization (slop) reservoir, which includes a pump, a guide block, connecting pipelines and a cutting head. The guide block is designed with flexible ribs. Polyurethane ribs are inserted into the slots of the case made of durable plastic, which contributes to the maximum reduction of the complexity in the process of replacing them. The plastic block for cutting in the cutting head is made of segments between which the knives are clamped. Standard knives have grooves necessary for their installation. For easy handling, each unit has a simple lever that provides good grip on the unit when it is removed from the housing.

The use of a water-cutting machine eliminates the need for a washing-shaking machine, in which starch and small particles are washed off from the surface of cut potatoes with tap water, as well as a solution of sodium bisulfite to preserve the color of the potato or sulfite.

In the production of dry mashed potatoes using double cooking potatoes. To do this, washed, inspected plates are fed into blancher 11 for preliminary boiling them with water at a temperature of 75–95 ° С for 10–20 min, blanched potatoes are cooled with running water in cooler 12, and boiled in steam cooking apparatus 13 at a temperature of 95–100 ° С within 20–35 minutes until fully prepared.

Blanching potatoes significantly changes its physico-chemical properties. The nature and intensity of these changes depends on the type of raw material, its chemical composition, mainly on the starch content in it. Blanching helps to remove air from the tuber tissue and ceases the activity of oxidative enzymes that destroy vitamins A and C and contribute to spoilage of the product, and also allows you to maintain its natural color and taste. The principle of operation of the blancher is as follows. The raw materials are loaded into buckets, which are transported through the tunnel by a conveyor. The buckets are immersed in hot water and at the end of the process they move the blanched product from the tunnel and direct it for cooling. Blanching times range from 2 to 32 minutes

The cooler has a bath with a conveyor, which moves the raw materials through a layer of water cooled to 0 ° C. A continuous change of water occurs in the cooler bath. The water inflow is regulated so that the temperature of the water leaving the bath is below the average final temperature of the product by 5 ... 10 ° C. Water consumption during cooling is 2 ... 4 l per 1 kg of product.

The cooking apparatus is a cylindrical working chamber in which the food product is moved using a screw conveyor. The auger conveyor (auger) is driven from the electric motor by means of a speed controller - a speed variator, which allows you to change the residence time of the food product in the steam chamber.

Steam is fed into the chamber, as a rule, under excessive pressure, so the loading and unloading devices have special sealing devices - turnstile gates.

To improve the consistency, color, increase the nutritional and biological value of dried mashed potatoes, it is possible to use various food, taste and biologically active additives that are introduced into the potato after cooking at the mixing stage. For this, additives come from metering devices 15.

Cooked potatoes are crushed in a screw potato masher 14 until a puree mass is obtained, mixed with a plasticizer added using a metering device 15, and then dried on a roller dryer 16 at a drum surface temperature of 140 ... 155 ° C for 20 ... 60 s to a product moisture of 8 ... 12%.

 Using special rolls, the product is applied in a thin layer on the outer wall of the drum. The dryer drum is heated from the inside using saturated steam. After one revolution of the dryer drum, the dry potato mass is removed using a special knife.

Part of the saturated steam during heat transfer condenses on the walls of the drum. Condensate formed is continuously discharged using a tube. The drum heating system is completely closed to prevent contact of the coolant with the product.

Short-term exposure to high temperatures on the potato mass reduces the possibility of product damage. Moisture evaporated during drying is discharged from the top of the unit to a circuit with the possible further use of the latent heat of phase transformation, for example, during steam condensation to heat water.

Dried mashed potatoes in the form of a thin sheet with a thickness of about 0.25 mm are ground during transportation, first using the conveyor of the chopper hopper 17, where it is subjected to preliminary large grinding, and then using a rotary mill 18 to change the degree of grinding and obtain the desired dry fractionation potato mass, which eliminates the need for a flocculant. The dried product is metered into the receiving hopper of the mill, from where it enters the zone of the internal rotor. Due to centrifugal forces from the rotation of the rotor, the material moves to the periphery, where it is crushed by grinding elements mounted on the rotors. The crushed material with air flow is discharged through the discharge port of the mill. The transport air flow is created due to the rotation of the external rotor. Together with the source material, air is taken through the receiving hopper for transporting the material.

 The resulting dried mashed potato is fed into the collection hopper 19, from where it is sent through magnetic traps 20 to the filling and packaging machine 21. The dried cereal is packed in paper bags with plastic liners.

Waste after the steam cleaning unit 5 and the drum washing and cleaning machine 8 is collected and subsequently sent to the processing site in the storage bins 22 for the production of the feed product.

Waste at the processing site is subjected to dehydration: first, mechanical due to pre-pressing on the press 23, and then thermal due to convective drying on a belt dryer 25.

The starch-containing secondary raw materials in the form of waste material are sent through the production line 3.1 from the main production line from the storage hopper 22 to the press 23, which carries out its intermediate preliminary dehydration. The product is pressed through a press into a compression chamber, where the material is subjected to even greater compression during its progressive movement along the chamber. Compression is achieved by reducing the volume between the turns of the press. The product exits the compression chamber through the discharge hopper. Next, the dehydrated starch-containing raw materials are transported through the conveyor line 3.2 by an intermediate conveyor (not shown in Fig. 1) to the storage tank 24. From the storage tank 24, with the help of an adjusting batcher (available above the dryer), the dehydrated starch-containing raw materials enter the belt dryer 25, where they are dried to a moisture content of 12 ... 14% at a temperature not exceeding 65-67 ° C. The dried product is transferred to the hopper-collector 26 with magnetic shielding via processing line 3.3, from where it is fed to the filling and packaging machine 27. At the waste processing section, it is planned to use the filling and packaging machine 27 of the same type as in the line for the production of dry mashed potatoes. Dried secondary raw materials have an increased feed value and are subsequently processed to produce complete feeds.

The line provides the possibility of complex processing of potato raw materials and can be used for the production of dry mashed potatoes in the form of flakes and grains with the processing of potato waste in the form of a feed product.

Thus, the use of the dry mashed potato production line allows you to:

- implement waste-free integrated processing of potatoes and, as a result, improve the environment and the environmental safety of production during the processing of potatoes due to the maximum utilization of potato waste;

- reduce the amount of waste through the use of a cutting machine, reduce the degree of contact with air oxygen due to the closed circuit of the cutting machine, which contributes to less darkening and lower organoleptic qualities of the finished product, as well as reduce specific energy costs;

- reduce the cost of primary products through the implementation of additional;

- to intensify the technological processes for the production of dry mashed potatoes with the reduction of additional equipment in the form of a washing-shaking machine and sulfitator;

- increase the degree of processing of potatoes and the yield of the main product.

Claims (1)

Dry mashed potato production line containing a weighing truck, weighing hopper, washing machine, inspection conveyor, steam cleaning unit, drum washing and cleaning machine, inspection conveyor, blanching machine, cooler, cooking machine, potato washer, roller dryer, collecting hopper with magnetic catchers, a filling and packaging machine, characterized in that it contains, after the steam cleaning unit, two screw conveyors, between which a brush machine is installed, after the drum a washer-cleaning machine with an inspection conveyor - a water-cutting machine, and after a roller dryer - a rotary-type mill with a separator for fractionating particles, while the line additionally provides a waste processing section, including waste storage bins, a press for preliminary mechanical dehydration of starch-containing raw materials, storage tank, convection belt dryer with an adjusting batcher, storage hopper with magnetic catchers and a packaging machine.

Images