Abstract:
Abstract: In order to improve the effective utilization of resources and solve the problem of energy consumption in the production, using residual heat (reducing the boiling time of noodles and then allowing them to stand and using residual heat to continue to cook) and changing the frozen condition were applied in developing energy-saving technologies of frozen noodles. Instead of boiling, which generally requires constant heating, utilization of residual heat in a closed pot following boiling is a well-known approach for cooking noodles but has never been investigated. The process parameters were optimized from the quality-related indices of textural properties, whiteness, pasting properties, and water distribution, and energy consumption and sensory evaluation were determined by texture analyzer, differential scanning calorimetry and low-field nuclear magnetic resonance.The usage of residual heat could not only increase the gelatinization ratio of noodles, but also decrease the cooking time and energy consumption. The whiteness values of frozen noodles gradually increased with the extension of standing time, but the differences were not obvious. There were no significant differences of the whiteness values with prolonged standing time both for 4 min in the case of boiling for 2 min and for 2 min in the case of boiling for 3 min. The textural properties of frozen noodles i.e. hardness, firmness and break strength increased firstly and then decreased with prolonged standing time. In the case of boiling for 2 min, the textural properties and whiteness values with standing for 6 min after that were higher than those of other standing time, whose gelatinization ratio reached 97%. For boiling for 3 min, the textural properties and whiteness values with standing for 4 min after that were higher than those of other standing time, whose gelatinization ratio reached 98%. There were significant differences of the textural properties (hardness, adhesiveness, springiness, cohesiveness, gumminess, chewiness, break strength and firmness) and relaxation time between the quick-freezing temperature of -40℃ and the temperature of -30℃. There were significant differences of the textural properties and relaxation time at different frozen time in the range of 15-25 min at -30℃. Similarly, there were significant differences of the textural properties and relaxation time at different frozen time in the range of 10-20 min at -40℃. The lightness, redness, yellowness and whiteness of noodles had significant differences between -40 and -30℃ during from 10 to 20 min. Along with the standing time extending, the lightness and whiteness values of frozen noodles appeared to increase, while the redness and yellowness values had opposite tendencies at the same frozen temperature. Again, the lightness, redness, yellowness and whiteness had significant differences at different frozen time from 15 to 25 min at -30℃, and also at different frozen time in the range of 10-20 min at -40℃. Overall, there were no significant differences in textural properties, whiteness and moisture distribution between freezing for 20 and 30 min at the temperature of -40℃ (traditional thawing pattern).Considering the energy and sensory evaluation, the processing of noodles that were boiled for 3 min followed by standing for 4 min and freezing for 20 min at -40℃ was chosen as energy-saving technology with the optimized parameters. The results showed that the energy-saving process cost 3.47 kW·h electric power per kilogram of product with the energy saving reaching 17.18% comparing with traditional technology. The total sensory score of energy-saving process was 85.5 and there were no significant differences in the sensory indicators including color, performance status, palatability, smoothness and taste between optimized and traditional technologies. Therefore, under the premise of guaranteeing the quality, the usage of residual heat and reduction of freezing time are partly effective for energy saving. This processing cost was analyzed by simulation calculations, in which the production cost saving was ¥805 per ton of frozen cooked noodles. The method and data stated in this study are valuable and useful to the industry and can provide reference for further studies, of energy-saving technologies of frozen noodles.