Yellow wine is a beautiful traditional cultural heritage of the Chinese nation. Although it has developed over the past millennium, it is still a glimpse of the south of the Yangtze River. Packaging containers for thousands of years are nothing more than kiln burning products such as pottery jars and porcelain jars. With the emergence and development of the modern silicate industry, the yellow wine has a glass bottled product, which makes the attractive amber color of the yellow wine come to the fore. However, the glass bottle has the same disadvantages as the above-mentioned fired product, which is self-contained and easily broken. The continuous improvement of the performance of modern organic polymer materials and the successful development of high temperature resistant, non-toxic and odorless, food hygiene grade polymers have made rice wine packaging a broader world. With the expansion of the sales area, there has been a strong impact and contradiction between the huge cost of long-distance transportation and the corporate purpose of giving profits to consumers. Long-distance transportation is not only costly, but also has a low volume ratio, and the pottery packaging is fragile and the wine loss is also large. It is packaged in a 2.5L plastic pot and has a high volume ratio and can hold 9,600 pots (net content: 24 tons). Therefore, the reason is self-evident.
Although altar wine has the advantage of long storage time, it is impossible for most consumers who buy and drink, but some shortcomings of altar wine have been revealed: the mud head is easy to loose and fall off, causing the wine to deteriorate. The pieces of broken mud and lotus leaf clams are easy to fall into the altar during the opening process, and are not hygienic. With the development of consumers in the market for ordinary bulk rice wine products, the trend of bottled wine replacing altar wine is irreversible, and enterprises and consumers are increasingly demanding.
In 2006, the barrel wine market suddenly emerged and became a highlight of rice wine sales. The so-called barreled wine, that is, a square or round 2.5L to 4L pot made of PP material is sold as a packaging container. The wine is positioned at the low-end consumer group. Once it is listed, it is favored by the mass consumers because of its low price, easy to buy and carry, and the empty pot can be reused. Gu Yue Longshan finds the market entry point and is determined to make a breakthrough in the hot filling technology of yellow wine and plastic pot. However, in the general alcoholic mechanized packaging line, automatic production in the whole process cannot be realized. The pioneering Gu Yue Longshan Company adheres to the concept of pioneering and innovation and the attitude of being responsible to consumers. On the one hand, it pays attention to the hygiene of production links, and operates according to the requirements of HACCP and ISO9000, ISO14000 and other systems to ensure the quality of filling products. Carry out bold exploration and experimentation on the filling process, thoughtfully analyze and analyze the production process and operation, fully design and demonstrate the installation and layout of equipment and pipelines, carefully arrange and transform the production environment, and actively Seek to develop a fully automatic filling line.
On October 8th, 2006, under the efforts of the technicians of the process and equipment special research team, the first domestic automatic filling line for barreled wine using hot filling technology was successfully trial-produced at Gu Yue Longshan No. 2 Brewery. The equipment mainly has the following characteristics:
Irrigation and filling machine
The flushing pot part is backwashed with food sanitation disinfectant. The rinse liquid is recycled and filtered, and the temperature is adjusted and adjusted to ensure the flushing effect. The filling part adopts high-temperature gravity micro-negative pressure and large-pitch rotary continuous filling mode, up to 1600BPH (2.5L), accurate liquid level control, real-time wine temperature detection according to hot filling process requirements, and long-term shutdown. After the maintenance, the temperature inside the wine machine drops to the lower limit of the temperature control, the reflux pump is automatically turned on, and the low temperature wine in the wine tank is discharged. After the production is resumed, the wine temperature is re-measured, and after the temperature control position is reached, the filling machine is started to ensure the filling. The constant temperature of the filling wine also ensures the consistency and eligibility of the product quality. The filling cylinder is a ring-shaped sealing cylinder, which is convenient for CIP cleaning. The inner container conveying of the machine adopts the pot neck positioning conveying, which can reduce the strength requirement of the container and reduce the container cost. The electrical control of the whole machine adopts PLC frequency conversion control.
2. Single head wide mouth sealing machine
The machine is also the first model in China, using aluminum foil film for thermal composite sealing, and the design capacity of a single film is positioned above 600 pots/hour. The whole machine integrates light, electricity and gas. It adopts PLC control, the sealing time is adjustable, the sealing temperature is adjustable, the heat sealing head is adjustable in height, and it can adapt to the sealing of large range height and large diameter polyester bottles, and the operation is simple.
3. Full pot leak detector
The method of tilting and slamming the leak detection is adopted, and the aluminum foil sealing is manually detected by the gravity load and the external pressing force of the product, and the aluminum foil is sterilized by the wine temperature to ensure the product quality. Production capacity: 1500BPH.
4. Single head positioning capping machine
The machine adopts the rotary gap movement to set the bottleneck to carry out the magnetic capping, the torque is adjustable, and the automatic cover, the cover detection system and the minimum bottle number linkage detection system solve the plastic pot different from the glass bottle material. Technical difficulties ensure that the quality of the closure during the closure process is relatively stable.
The use of the production line marks that Gu Yue Longshan has taken the lead in conquering the low-efficiency and low-yield manual filling production mode of plastic pot barrels in the yellow wine industry. It has entered the ranks of mechanized automatic production, and the product quality will be more perfect. After several months of commissioning and putting into mass production, the operation of the assembly line is basically normal, the number of employees is reduced, and the production capacity is greatly improved. Of course, the birth of any new thing will have problems and deficiencies of one kind or another. After summarizing, there are still many spaces in the production line that need to be improved and deepened. We believe:
(1) In terms of equipment: the aluminum foil sealing machine must solve the problem that the plastic pot is heated (the filling temperature reaches about 85 °C), the body is softened, the front and rear pot extrusion deformation is not easy to locate, the conveyor belt at the junction is shaking, and the positioning seal is stopped. Technical difficulties such as shaking. This problem is the technical focus of the entire filling line, which will affect the continuity of the production process and limit the increase in production. Equipment manufacturer design technicians should try to improve the sealing speed and sealing quality of the machine and reduce the failure repair rate.
(2) In terms of packaging materials: the design of the pot shape and the local structural shape also play a vital role in the smooth operation of the filling line. For example, if the 4L product is full of pots and the self-weight reaches 4Kg or more, the bottle neck bottleneck strength becomes the main problem of filling liquid level and capacity control; in the design of the pot, if the handle position of the pot handle is too close to the bottle mouth , it will hinder the cutting of the capping fork, affecting the quality of the cap, resulting in missing or high-cover products; for square pot products, the spout should be centered as much as possible, otherwise the positioning of the pot in the filling and capping will bring Great difficulty, resulting in higher scrap rate; in the filling high temperature, the rigidity of the kettle body is weakened, the kettle body is expanded, causing the capacity to be out of control, and the metering tolerance is a problem to be solved. These defects cause the attention of the plastic pot manufacturers. Pay attention to it.
(3) In the hot filling process: further exploration and adjustment of the process parameters is required to minimize the filling temperature, which can not only save energy but also appropriately reduce the requirements for excessive equipment and packaging materials.
(4) In terms of supporting equipment: At present, the function of the line only covers the automatic cover, and the labeling, packing and sealing links remain in the manual operation mode. After the products are off the assembly line, they cannot be directly stored in the warehouse. They still need to be stacked on site, and then manually labeled, sealed, and palletized. The site and personnel requirements of these links cannot be liberated, and there are bottlenecks in production.
In summary, the successful production of Gu Yue Longshan plastic pot yellow wine hot filling production line, in the industry itself is a development and innovation of technical equipment, condensed the efforts of the management and technical staff, will promote the development of the yellow wine industry. The high speed of production eases the contradiction between supply and demand of barreled wine on the market; the high efficiency of production reduces the cost of the product and benefits the consumers; the automatic filling process completely solves the problem of product quality stability. "Practice is the standard for testing truth." The production line will be tested in the future large-scale production, constantly improving, and constantly improving the technical content.
Author unit: Zhejiang Gu Yue Longshan Shaoxing Wine Co., Ltd.
What is Food additive?
Food additives refer to chemical synthetic substances or natural substances intentionally added to food in order to improve the quality, color, aroma, and taste of food, as well as for the needs of anti-corrosion and processing technology. These additives are usually added in small amounts during the food production process to enhance the sensory properties, stability, safety or convenience of the food.
The functional classification of food additives includes but is not limited to the following:
1. Acidity regulator: used to maintain the acid-base balance of food.
2. Anti-caking agent: prevent food ingredients from clumping or aggregating.
3. Defoamer: Reduce or eliminate foam in the food production process.
4. Antioxidants: prevent food oxidation and deterioration, extend shelf life.
5. Bleach: used to improve the color of food.
6. Leavening agent: make the food expand during cooking or baking.
7. Base agent substances in gum-based candies: ingredients that provide a gelatinous texture.
8. Colorants: give food a specific color.
9. Color protectants: Protect food color from oxidation or other factors.
10. Emulsifier: help oil and water and other insoluble substances mix evenly.
11. Enzyme preparations: used to catalyze specific reactions in food processing.
12. Flavor enhancer: enhances or improves the taste of food.
13. Flour treatment agent: Improve the processing performance of flour.
14. Film agent: Form a protective film on the surface of the food to prevent drying or oxidation.
15. Moisture retention agent: to maintain the moisture content of food, affecting its taste and shelf life.
16. Nutritional fortifier: Increase the nutritional value of food, such as adding vitamins or minerals.
17. Preservatives: prevent food from spoilage and extend shelf life.
18. Stabilizers and coagulants: improve the stability of food or make it solidify.
19. Sweeteners: Provide sweet taste and can be natural or artificial.
20. Thickener: increase the viscosity or thickness of food.
21. Edible flavors: Provide or enhance the aroma of food.
22. Processing AIDS for the food industry: substances that play an auxiliary role in the food processing process.
The definition and regulation of food additives may vary from country to country, but in general, their use must comply with relevant food safety regulations and standards to ensure that the specified amount of use will not cause adverse effects on the health of consumers. The Joint Food Regulatory Committee of the Food and Agriculture Organization of the United Nations (FAO) and the World Health Organization (WHO) has also defined and classified food additives.
Food Additive, Health food ingredient, Nutritional Supplements, Dietary Supplements
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