Beaf Freeze Dryer

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Beaf freeze dryer

At present, freeze-drying machines are used in many food industries, such as dietary health food and pet food. Today, let's introduce the freeze-drying process of freeze-dried meat and beef. The technological process, technological conditions and operation points of freeze-dried beef processing are designed to provide reference for better production and processing of freeze-dried beef products.

1、 Process flow

Frozen meat / (fresh meat) → thawing → cleaning → segmentation → mincing → batching and rolling meat → enema molding → cooking → cooling → demoulding → precooling → slicing → selection → loading → quick freezing → vacuum drying → material selection → gold detection → packaging → finished products.

2、 Process conditions and requirements

(1) raw materials

The raw material is beef with reddish color, no sticky deterioration, fine meat quality and good compactness. The raw materials determined as unqualified by inspection shall be handled according to relevant regulations. The place where raw materials are stacked must be cleaned without dirt and peculiar smell. The natural thawing storage time of frozen beef at room temperature is 2 days in winter and 1 day in summer. The thawed beef transferred to the workshop must be processed on the same day. Fresh beef entering the factory must be processed on the same day. If the frozen beef is processed within one week, the storage temperature can be controlled between 0 ~ 2 ℃ and the humidity can be controlled between 86% ~ 95%. If the beef cannot be processed within one week, it must be transferred to a low-temperature warehouse below - 18 ℃.

(2) thawing and cleaning

① Thawing tank and turnover box must be cleaned and disinfected before use. The packaging of frozen meat must be cleaned out of the workshop immediately to avoid cross contamination. ② The residual chlorine content in the water is 0.05mg/l ~ 0.3mg/l. Or thaw with cooking cooling water, and the water temperature is lower than 28 ° C. When the frozen meat is thawed for 12 h ~ 32 h, the water shall be connected with a plastic pipe and inserted into the bottom, and the water shall flow out from bottom to top. Thaw until the center of the meat becomes soft and there is no ice crystal. ③ Wash the meat until it is free of dirt and impurities. Broken meat must be washed piece by piece. Clean the fresh beef with flowing water. The meat in the trough must be fished clean.

(3) segmentation

① Before segmentation, the operating table, dividing knife (derusting), vegetable board and turnover box containing beef must be cleaned and disinfected with sodium hypochlorite solution with mass fraction of 1x10-4. ② Remove the large fat and fascia in the meat, and divide the beef into (length x width x thickness) (20 ~ 30) CMX (5 ~ 10) CMX (2 ~ 5) cm meat pieces.

(4) stranding

① Before mincing, check whether the meat grinder is normal. After confirmation, disassemble, clean and disinfect the parts directly in contact with the meat. ② Correctly select twisted parts of different specifications according to regulations. To prevent the meat from splashing, cover the outlet with 30cm casing or plastic cylinder. Under continuous working conditions, the meat grinder and tools shall be cleaned and disinfected every 4H. ③ The twisted meat shall be stored in the hopper car, and the twisted fascia shall be stored in the turnover box, and the storage capacity of each basket shall be less than 40kg. ④ The minced meat shall not be stored in the rolling room for more than 12 hours, and shall be marked. Each batch of products shall be stacked separately.

(5) batching

All kinds of auxiliary materials shall enter the batching room, be padded with plastic backing plates and stacked neatly. The interval of each kind of auxiliary material shall not be less than 20 cm. The name of auxiliary materials shall be clear and the identification shall be eye-catching. The tools and instruments used for batching must be cleaned and disinfected, and the residual chlorine content of the water is required to be 0.05 mg / L ~ 0.3 mg / L. Before batching, the master shall check the quality of various auxiliary materials. Before weighing auxiliary materials, the weighing instrument shall be calibrated. The error of the weighing instrument shall be 1 g within 5kg, 100 g within 50kg and 200 g above 50kg.

(6) roll out the tank

① The tools and instruments used for entering the tank must be cleaned and disinfected. Mix the prepared auxiliary materials evenly with a mixer to completely dissolve them. Before rolling, check whether the rolling machine operates normally and whether the vacuum gauge is intact. After confirming that it can be used, clean the rolling tank and disinfect it with 1x10-4 sodium hypochlorite solution before entering the tank.

② Pour the ground meat into the jar. Use the meat truck to transfer the evenly mixed excipients into the rolling room, and then pour them into the pot. The vacuum pipe of the sealed rolling tank shall be connected, the power supply shall be connected, and the vacuum pump shall be started. The vacuum degree shall be 65 kPa ~ 85 kPa. Roll and knead forward for 15 min and stop for 15 min; Reverse for 15min and stop for 15min; Repeat the cycle. The temperature of the rolling room shall be controlled between 0 ~ 5 ° C. the temperature and vacuum degree shall be checked every 1H. When the vacuum degree is lower than the specified value, the vacuum shall be supplemented in time; When the temperature is higher or lower than the specified value, adjust the temperature in time and make records. The rolling time is 8 h.

③ After the first rolling and kneading, break the vacuum, open the rolling and kneading tank, observe the color of the product out of the tank, measure the temperature of beef before it is out of the tank, and make records before it can be out of the tank.

④ In the case of continuous production, the rolling tank shall be cleaned every two days. When changing the product type, the rolling tank must be cleaned.

(7) can bowel molding

① Before mold making, the mold and cooking bag shall be sterilized at high temperature, the operating table shall be cleaned, and the sodium hypochlorite solution with mass fraction of 1x10-4 shall be used for disinfection.

② When making the mold, put the plastic bag flat into the mold, pack the meat until it is flat with the mold, take it out and knead it tightly, release the air between the meat and the meat with a needle, and cover the mold cover with uniform force, and the meat cannot be extruded.

③ If the enema machine mold is used, the master shall first clean the external and internal parts of the enema machine in contact with meat, and disinfect it with sodium hypochlorite solution with mass fraction of 1x10-4 before use. The molded beef must be transferred to the cooking process in time.

④ After the completion of mold making, check whether the number of exhaust needles (punch pins) is consistent with the received quantity, make records, and record the use, accumulation and loss of mold bags (casings) and steel ball collars.

(8) cooking

① Clean the cooking tank without scaling and dirt. The central thermometer and the thermometer for measuring water temperature must be calibrated before use. Check whether the mold is pressed well, and then gently put the mold into the sandwich pot and cooking tank. The water to be put in shall be submerged over the die surface. ② Cook. Heat and maintain the water temperature at 90 ~ 95 ° C. The cooking time of each pot is about 3 hours. When the water temperature reaches 90 - 95 ° C, measure the water temperature every 20 minutes. After cooking for 2 hours, measure the central temperature every 20 minutes. When it reaches 75 ° C, turn off the steam valve, start the mold and make temperature measurement records every time. ③ The cooking time of each pot shall not exceed 30 min.

(9) cooling, demoulding and precooling

① The residual chlorine content of cooling water is required to be 0.05 mg / L ~ 0.3mg/l, without color and odor. The cooling pool must be cleaned and cooled with flowing water. Before starting the pot, put the water to 2 / 3 of the capacity of the cooling pool. Put the cooked beef into the cooling water and handle it gently. The cooling time is 1H ~ 2H. The mold can be demoulded only when the cooling water temperature is lower than 25 ° C and the center temperature of the meat mold is lower than 40 ° C.

② Before demoulding, the master shall first clean and disinfect the precooling room, console, turnover box, apron and sleeve, and demould quickly. Put the moulded meat into the turnover box after cleaning and disinfection. There is a certain interval between the meat and the meat pieces. The meat pieces are generally stacked in the box for no more than two layers and should be handled with care. The meat pieces removed from the mold must be transferred to the precooling room within 10min. Beef transferred to the precooling room shall be stacked in each batch d with clear identification. After demoulding, clear the number of buckles, verify whether it is consistent with the quantity transferred in the previous process, prevent casing and buckles from mixing into meat, and make records of the use and recycling of buckles. The temperature of precooling room shall be controlled between 0 ~ 5 ° C.

(10) Slicing tray

① Before slicing, clean the trolley, console, tray, external and internal parts of the Dicer in contact with meat, and disinfect with sodium hypochlorite disinfectant with mass fraction of 1x10-4. The tools and instruments must be cleaned and disinfected every 4 hours of continuous operation. Check whether the slicer operates normally, and operate after confirming that the specification of the knife grid is qualified.

② The meat can be sliced only when the central temperature reaches 0 ~ 2 ° C. Slice specification (length x width x height) 9mmx9mmx3mm, which can be sliced according to customer requirements under special circumstances. During slicing, the thickness of meat slices and whether the forming rate meet the requirements of the control point shall be checked at any time. During the slicing process, check the parts (copper sleeves and screws) that are easy to fall off from the cutting machine every 1 h, and make inspection records. If necessary, tighten or replace the parts in time. The slicing can be restarted only after confirming that they are intact.

③ Clean disinfection towel must be used to wipe the water drops adhered to the tray and workbench before they can be used for loading. Each plate is measured at 5 kg, with a positive and negative error of 50 G. The thickness of the pallet shall be uniform and the force shall be appropriate. It shall not be pressed, and the bottom and edge of the pallet shall not be stuck with materials. Ensure that the qualified rate of products reaches more than 95%.

④ When inserting a plate, one plate shall be placed on each side of the rack in turn. The slicing time of each vehicle shall not exceed 1.5 h. Each full cut vehicle must enter the tunnel immediately, fill in the quick freezing record, and indicate the warehousing time, batch number, quantity (coil number), unwheeling number, etc.

(11) Quick freezing

The tunnel must be cleaned and disinfected without dirt and impurities. The tunnel temperature shall be kept below - 18 ° C and the freezing time shall not be less than 6h. The unwheeling shall be arranged in an orderly manner to achieve first in first out. During continuous production, the tunnel shall be kept clean at any time. During shutdown, the tunnel must be completely cleaned and disinfected with sodium hypochlorite solution with mass fraction of 1x10-4. The personnel in the control room shall flush the frost according to the frosting condition. During frost flushing, prevent the frost flushing water from polluting materials and keep the discharge of frost flushing water unblocked.

(12) Freeze drying

Before entering the warehouse, wipe the lyophilized warehouse with a towel moistened with disinfectant with mass fraction of 1x10-4, and the outer wall of the tank shall be kept clean. It is confirmed that the relevant equipment, steam pressure, heating plate temperature, loading quantity of meat slices, freezing temperature, freezing time and other relevant technical parameters of the freeze-drying warehouse meet the freeze-drying requirements and operate according to the freeze-drying curve. During the working period, the pre-treatment and post-treatment personnel shall not cross post to avoid cross pollution.

(13) Discharging

① Ozone sterilization shall be carried out in the post-treatment area 24 hours before each production. The unloading packing room must be clean and sanitary, and the humidity shall be less than 60%. The discharging personnel must wear masks and disposable gloves and dress neatly. ② After vacuum drying, less than 0.5% of the dry can be taken out of the warehouse. If more than 0.5% of the dry should be returned to the warehouse for treatment. ③ After leaving the warehouse, the meat slices shall be unloaded after natural cooling for 20min. The personnel in and out of the warehouse must close the sealing door at any time.

(14) Jintan packaging

① The temperature of Jintan packing room shall be 20 ~ 25 ℃, the humidity shall be less than 60%, and the ground shall be kept clean and dust-free at any time. Before gold detection, the master shall check whether the metal detector is normal and can be used only after confirmation. Firstly, use the standard iron sample with diameter of 1.0 mm to test its sensitivity. After passing the test, wet the towel with disinfectant with mass fraction of 1x10-4, and then wipe the conveyor belt clean.

② During gold exploration, the materials shall be placed evenly. The materials shunted by gold exploration must be re gold explored. Only the materials that cannot be detected after gold exploration to Z will be reported. The sensitivity of the gold detector shall be tested every 30 min during the gold exploration.

③ The weighing shall be accurate. The net weight of each piece shall be 10 kg with an error of 0.05 kg. It shall be packed in double layers and vacuum pumped until the plastic bag is just pasted with the package. After the sensory test is qualified, the certificate of conformity shall be pasted, and a product identification shall be pasted on the plastic bag and carton respectively.

(15) Inspection and warehousing

Each batch of products shall be inspected after processing, and the products can be delivered only after all indexes meet the standards. The forming rate, color, taste, smell and net quality of each box shall be inspected by the on-site quality inspector.

The temperature of finished product warehouse is 0 ~ 25 ℃ and the humidity is less than 60%. The warehouse must be clean, dry, dust-free and rat free. Finished products shall not be placed directly on the ground, with clean plastic backing plates under them, and the stacking height shall not exceed 8 layers. Products that fail to pass the inspection of finished products shall not leave the factory.

Parameter：

Model	KFD-1	KFD-2	KFD-5	KFD-6	KFD-8	KFD-10
Capacity (Kg/Batch)	10	20	50	60	80	100
Shelf Area (㎡)	1.1	2	5	6	8	10
Shelf Size (Mm)	500*400	700*500	800*895	950*800	1000*800	1190*800
Shelf Quantity (Layer)	5+1	6+1	7+1	8+1	10+1	11+1
Shelf Temperature (℃)	-60 to +70
Water Catcher Temper (℃)	-65±5
Max Catch Water（Kg）	15	30	75	90	120	150
Ultimate Vacuum	1	1	1	2	2	2
Electricity（Kw）	12	16	22	34	34	41
Size（Mm）	2200*1000*2000	2500*1000*2300	2200*1200*2400	3500*1400*2430	3500*1400*2430	4540*1400*2450
Weight（Kg）	1500	2000	2500	3000	3500	3800

Pre-sale:

* As soon as we get your inquiry, we will always reply to your email on time and try our best to recommend you the most suitable freeze dryer. Detailed tech-info will also be provided for you.

* We can do sample test for customers.

After-sale:

* If possible, please do come to our factory and we will teach workers the whole process of freeze drying. The most appropriate time needed for freeze drying will be tested by us.

* We will keep in touch with you, to make sure every parts of the freeze dryer work well. One year warranty, free online service for abroad customers.

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