电磁内热式绿茶毛火工艺参数优化与分析

    Analysis and parameter optimization of first-drying process using chain plate dryer with electromagnetic heating for green tea

    • 摘要: 为探究新型绿茶电磁内热式毛火工艺对绿茶毛火效果的影响,该文应用正交设计和极差分析,以毛火样的生化成分含量和成品样的感官品质为目标值,对电磁内热式毛火工艺参数(热风温度、热风风机转速、链板传动转速等)进行优化,获得最佳参数,并与传统的燃煤式热风毛火、理条机毛火、电热管式热风毛火等在毛火效果和设备性能方面进行比较,结果表明:综合品质生化成分和感官评审的结果,电磁内热式毛火工艺的最佳参数组合为:热风温度115 ℃,热风风机转速1 200 r/min,链板传动转速1 050 r/min,3因素中以热风风机风速对绿茶毛火效果的影响最为显著;在此毛火条件下所制提香样的氨基酸、茶多酚、叶绿素、可溶性糖、儿茶素和咖啡碱的含量分别达2.31%、17.61%、1.13 mg/g、5.01%、10.74%、2.01%,品质物质加权值为7.66%,均高于其他3种毛火工艺;此工艺下所制成品茶样的外形、汤色、香气、滋味等均得到显著提升,感官总分达86.40,显著优于其他毛火处理;该毛火工艺能耗成本仅0.76元/kg,较电热管式热风毛火减少了70%以上,升温快,预热时间仅10 min,较传统燃煤式热风毛火的预热时间减少约50%,余热回收装置的设计显著提升了热能利用率,热效率提升50%以上;同时,生产效率达150 kg/h,较传统电热管式热风毛火提升3倍以上,而且温控精准和稳定、热风分布均匀。该研究可为茶叶加工提供技术参考和理论指导。

       

      Abstract: Abstract: Drying is the last process in each category of tea processing, which includes first-drying and final-firing, and first-drying is more essential. The role of first-drying is evaporating water content in tea products, and more importantly, promoting the occurrence of the thermochemical reaction at the same time. The reaction promotes the transformation and improvement of quality substances, and the formation of excellent aroma, taste, color and other tea qualities. At present, the main use of first-drying technology in the current production includes hot air first-drying technology, carding machine first-drying technology, microwave first-drying technology, low temperature vacuum drying technology, and so on. Although the existing first-drying technologies can enhance the flavor and taste quality of tea with different degrees, they mostly have low thermal efficiency, inaccurate temperature controlling, uneven heat distribution, poor and unstable quality, and other issues. For these reasons, based on the hot air first-drying technology that is the most widely used, our team has adopted a new type of electromagnetic heating technology, the waste heat recovery unit and oil-air exchanger to develop the chain plate dryer with electromagnetic heat (China patent number: ZL201420816998.8), in order to enhance the tea flavor and taste quality, obtain stable and high-quality tea, and at the same time enhance the thermal efficiency and production efficiency. The structure composition and technical characteristics of this chain plate dryer with electromagnetic heat were introduced in this article. Then the parameters of this new first-drying technology of green tea were optimized. In order to explore the influence of hot air first-drying process with electromagnetic heat on the quality of green tea, based on the results of previous single factor experiments, using main biochemical composition contents of first-drying samples and sensory evaluation score of made tea as investigation index, the orthogonal design and extreme analysis were used to optimize process parameters (hot air temperature, hot air wind speed, transmission speed, and so on) of chain plate dryer with electromagnetic heat. And the new first-drying technology was compared with hot air first-drying with coal as fuel, first-drying with tea carding machine, and hot air first-drying with electric heating tube. According to the results of quality biochemical composition and sensory evaluation, the optimal first-drying parameters combination of chain plate dryer with electromagnetic heat was determined as follows: Hot air temperature was 115 ℃, hot air wind speed was 1 200 r/min, and transmission speed was 1 050 r/min, and the most significant factor in these 3 factors was hot air wind speed. With these process parameters, amino acids, tea polyphenols, chlorophyll, soluble sugar, catechins, and caffeine of first-drying samples reached 2.31%, 17.61%, 1.13 mg/g, 5.01%, 10.74% and 2.01%, respectively, and quality material weighted value was 7.66%, which was significantly higher than the other processes. And the shape, color, taste, and aroma of made tea with the new first-drying technology were the best and the sensory quality score was 86.40, which was significantly higher than other first-drying methods. The energy consumption was 0.76 yuan/kg, which reduced by more than 70% compared with hot air first-drying with electric heating tube; the temperature rose very rapidly, and warming time was only 10 min, which reduced by more than 50% compared with traditional hot air first-drying with coal as fuel; the design of the waste heat recovery device greatly improved the utilization rate of heat energy, and the thermal efficiency was up to 50%; and the production efficiency was 150 kg/h, which was more than 3 times higher than the traditional hot air first-drying with electric heating tube, and meanwhile, the precise and stable control of temperature and the uniform distribution of hot air established solid foundation for obtaining high quality and stable tea quality.

       

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