Переглянути презентацію “Теплове оброблення м’ясопродуктів“
Варіння – теплове оброблення м’яса і м’ясопродуктів до стану кулінарної готовності у воді, гострою парою чи сумішшю насиченої пари і повітря, за температури близько 100°С у спеціальних камерах, відкритих котлах, автоклавах, під тиском і електромагнітним полем СВЧ.
Найпоширенішим є теплове оброблення парою завдяки меншим втратам маси і можливості одержати більш соковитий продукт, ніж при варінні у воді. Варінню парою піддають значну частину м’ясних продуктів, за винятком сирокопчених і копчено-запечених. Для варіння застосовують обладнання періодичної (котли, ванни, камери) і безперервної (бланшувальні машини, термокоагулятори) дії. М’ясопродукти у воді варять у котлах різної конструкції із завантаженням і вивантаженням уручну або спеціальними пристроями з перекидним і неперекидним резервуарами. За конструкцією і особливостями теплообмінних процесів котли варильні поділяють на: відкриті одностінні; відкриті двостінні; закриті двостінні.
У конструкціях одностінних котлів застосовано відкритий вогневий нагрів варильної місткості, а в двостінних теплоносієм є, як правило, водяна пара. Котли називають відкритими у випадку, коли в середині варильної місткості тиск близький до атмосферного, в закритих варильних котлах тиск у варильній місткості, як правило, манометричний, хоча існують вакуумвипарювальні котли, у яких тиск нижче атмосферного.
Котел Г2-ФВА (рисунок 1) з перекидним резервуаром з оболонкою спирається через цапфи на стійки. До цапф приєднані труби для підведення пари в оболонку і відведення конденсату. На цапфі розміщується черв’ячне колесо для повертання резервуара.
Рисунок 1 – Котел Г2–ФВА:
– резервуар; 2, 13 – цапфи; 3, 11 – підшипники; 4 – труба для відведення конденсату; 5, 9 – стояки; 6 – труба для виведення конденсату; 7 – оболонка; 8 – маховик; 10 – черв’як; 12 – труба для підведення пари; 14 – черв’ячне колесо
Застосовують також котли «Вулкан», К7-ФВ2А та К7-ФВ3-Е й інші, що відрізняються конструкцією котлів, їх кількістю та тиском обробки (відкриті та закриті котли, що працюють під тиском чи за умов вакууму).
Серед закритих двостінних котлів найчастіше застосовують котел варильний електричний типу КЕ-160. Крім котла КЕ-160 серійно випускаються аналогічні котли КЕ-100 і КЕ-250, які відрізняються об’ємом варильної посудини котла (відповідно 100 і 250 л), а також деякими експлуатаційними параметрами та габаритними розмірами. Технологічні процеси роботи котлів КЕ-100, КЕ-160 і КЕ-250 – аналогічні.
Технічна характеристика варильних котлів надана у таблиці 1.
Таблиця 1 – Технічна характеристика варильних котлів
| Показник | Г2-ФВА | К7–ФВ2А | К7– ФВ3–Е | КЕ-160 |
| Місткість (загальна), м3 | 0,6 | 0,46 | 1,1 | 0,16 |
| Тиск пари в оболонці, МПа | 0,05 | 0,07 | 0,3 | 0,001-0,045 |
| Температура води під час варіння, °С | до 100 | 80 – 100 | 85 – 100 | 85 – 100 |
| Займаєма площа, м2 | 3,0 | 2,3 | 3,2 | 1,1 |
| Маса, кг | 490 | 240 | 700 | 222 |
Котел варильний електричний типу КЕ-160 є закритим двостінним. Призначений для варіння ковбасних виробів, приготування бульйонів, овочів, гарнірів з використанням функціональних ємностей.
Рисунок 2 – Котел вварильний електричного типу КЕ-160
Котел (рисунок 2) складається з металевої обичайки 8, варильної посудини 10, що змонтовані на рамі 19. Ззовні обичайка закрита теплоізоляцією 9 із гофрованої фольги. Знизу до обичайки приварений парогенератор 18, в середині якого розміщені електронагрівачі 17. Рівень води, що заливається у парогенератор через горловину його контролюється краном 15. Захист електронагрівачів від “сухого ходу” забезпечується датчиком рівня води 24.
Вода в варильну посудину подається через кран 4. Злив вмісту із варильної посудини здійснюється за допомогою зливного крана 1 або 25. Отвір до зливних кранів, розташований у середині варильної посудини, закривається змінним фільтром 16. Варильна посудина закривається кришкою 3. У діапазоні від 30° до 90° пружинний пристрій підтримує її у відкритому положенні.
На кришці встановлено перепускний клапан 2, який призначений для регулювання тиску у варильній посудині. Відбивач 13 запобігає засміченню перепускного клапана. До варильного краю варильної посудини кришка притискається накидними важелями 14.
Замкнутий простір між варильною посудиною і обичайкою з парогенератором служить пароводяною оболонкою. Тиск у пароводяній оболонці підтримується за допомогою датчика-реле тиску 21, а контролюється – вакуумметром 5. Межі настроювання реле тиску наступні: для котла КЕ-160 нижня межа – 0,005 МПа (0,05 кгс/см2), верхня – 0,035 МПа (0,35 кгс/см2).
Для запобігання підвищення тиску більше 0,05 МПа (0,5 кгс/см2) служить запобіжний клапан 12. До рами 19 прикріплене облицювання 22, 23, 26 і панель 6, на яку виведені елементи управління і сигналізації котла. Режим роботи котла задається вручну перемикачем 7.
Принцип роботи котла полягає у наступному. Залита в парогенератор вода нагрівається електронагрівачами до кипіння. Пара, що утворюється, витісняє із пароводяної оболонки повітря, яке виходить через запобіжний клапан, при цьому ручка клапана повинна бути повернута стрілкою уверх. Пара, що продовжує утворюватись, створює в оболонці надлишковий тиск.
При досягненні верхньої заданої межі тиску реле тиску автоматично вимикає частину або всі електронагрівачі в залежності від вибраного режиму роботи котла.
Для котлів передбачені три режими роботи: режим “1” – варіння; режим “2” – розігрів; режим “3” – варіння з допомогою пари.
При режимі “1” котел вмикається на повну потужність, при досягненні надлишкового тиску в оболонці верхньої заданої межі він автоматично перемикається на 1/6 потужності. При зменшенні надлишкового тиску до нижньої заданої межі котел знову автоматично перемикається на повну потужність і далі цикл повторюється.
При режимі “2” котел вмикається на повну потужність і після того, як надлишковий тиск в оболонці досягає верхньої заданої межі, котел вимикається.
При режимі “3” котел вмикається на повну потужність і, коли надлишковий тиск в оболонці досягає верхньої заданої межі, він автоматично перемикається на 1/6 потужності. Після цього надлишковий тиск поступово знижується і при досягненні нижньої заданої межі, котел автоматично перемикається на 1/2 потужності. При досягненні верхньої заданої межі надлишкового тиску котел знову перемикається на 1/6 потужності і далі цикл повторюється.
Котел КЕ-160 може використовуватись для приготування бульйонів з кісток при оснащенні його додатковим обладнанням (Рисунок 3). У комплект додаткового обладнання входять: візок 1 та касети 2 з перфорованими ємностями. Застосування цього обладнання дає можливість знизити затрати ручної праці при реалізації маловідходних і безвідходних технологій переробки м’яса.
Рисунок 3 – Котел КЕ-160 з додатковим обладнанням:
1 – візок; 2- касета; 3 – захвати каретки; 4 – ручка редуктора
При варінні бульйонів подрібнені кістки закладаються у дві перфоровані ємності, які закриваються кришками і встановлюються у касету. (Кожна перфорована ємність вміщує в собі до 15 кг подрібнених кісток). Потім візок підкочується до завантаженої касети, яка фіксується захватами каретки 3 візка. При обертанні ручки редуктора 4 візка за годинниковою стрілкою касета піднімається до крайнього верхнього положення, підводиться з допомогою візка до котла. Для завантаження і розвантаження касет з функціональними ємностями використовується візок підйомний ТП-80К. Візок підкочується до котла так, щоб касета опинилась над варильною посудиною котла. При обертанні ручки редуктора візка проти годинникової стрілки касета опускається у варильну посудину. Після опускання касети у посудину звільняються захвати і візок відкочується від котла.
Далі необхідно провести наступні операції:
- залити в варильну посудину холодну воду в кількості 100 л для КЕ-160 (для КЕ-100 – 60 л, для КЕ-250 – 150 л води);
- перевірити роботу перепускного клапана на кришці, повернувши його ручку 2-3 рази навколо вісі і встановити в положення “0”;
- включити котел, повернувши на панелі ручку перемикача за годинниковою стрілкою у положення “1”, при цьому повинна загорітися лампа;
- прикрити кришку з фіксацією її на один із передніх накидних важелів;
- при появленні рівного і неперервного струменя пари із запобіжного клапана закрити клапан, повернувши його ручку стрілкою униз;
- видалити жир і піну, що утворюється на поверхні бульйону;
- після видалення жиру і піни кришку рівномірно притиснути всіма накидними важелями.
Через три-чотири години варіння слід вийняти касети з ємностями. Виймання касет із варильної посудини котла проводити наступним чином:
- вимкнути котел поворотом ручки перемикача в положення “0“;
- відкрити обережно кришку котла, відвернувши накидні важелі;
- підкотити візок до котла, зафіксувати касету захватами, витягнути її із варильної посудини, підняти каретку в крайнє верхнє положення і залишити в цьому положенні на декілька хвилин для стікання бульйону;
- відкотити візок з касетою від котла до столу для розділення костей.
При необхідності переливу бульйону і інших рідин із варильної посудини в функціональні ємності, які встановлені в пересувні котли, кришку котла слід закрити і загерметизувати за допомогою накидних важелів. При кипінні рідини в варильному котлі створюється надлишковий тиск, у результаті чого здійснюється переливання (витискання) вмісту із варильної посудини в пересувний котел. Пересувний котел, в який здійснюють переливання, слід встановити над ємністю. Ручка перепускного клапана повинна бути встановлена в положення “0”. Після вмикання котла в режим “варіння” і закипання рідини необхідно ручку перепускного клапана встановити в положення “3”. У варильній посудині створюється надлишковий тиск, в результаті чого починається переливання. Для призупинення переливання ручку переливного клапана необхідно встановити в положення “0”.
При відсутності інтенсивного витискання бульйону ручку запобіжного клапана повернути в положення стрілкою вверх і тримати відкритим клапан до тих пір, поки стрілка вакуумметра не переміститься до відмітки, близької до нуля. Після цього клапан закрити поворотом ручки в положення стрілкою вниз. Процес витискання рідини прискориться.
В апараті безперервної дії (рисунок 4) варять м’ясну сировину в шматках. Він має вигляд ванни з циліндричним днищем і кришкою. У середині ванни обертається шнек, що переміщує у процесі варіння шматки м’яса від місця завантаження до місця вивантаження. Шнек обертається електроприводом. Ванна заповнюється на 70 % за висотою гарячою водою, яка підігрівається гострою парою, що виходить з барботера, розташованого на днищі ванни.
Рисунок 4 – Апарат безперервної дії для варіння м’яса в шматках:
1 – привід; 2 – ванна; 3 – кришка; 4 – шнек; 5 – отвір для вивантаження; 6 – трубопровід; 7 – днище
Термокоагулятор Я6–ФПК (рисунок 5) застосовують для безперервного теплового оброблення фаршевих м’ясопродуктів.
Він складається з циліндричного корпусу з патрубком для подавання продукту і лотком для його вивантаження, а також з патрубками для подавання пари, що розташовані на зовнішній поверхні корпусу в кілька рядів і з’єднані між собою паропровідним колектором. У корпусі концентрично розміщений шнек із прорізами.
Термокоагулятор працює так. Фарш подається насосом через патрубок 2 у корпус і переміщається шнеком у бік вивантаження. Гостра пара, що подається у колектор і розподіляється по форсунках, надходить безпосередньо до продукту. При конденсуванні пара нагріває сировину, причому нагрівання здійснюється по всьому об’єму продукту. Одночасно відбувається процес перемішування.
Рисунок 5 – Термокоагулятор Я6 – ФПК:
1 – задня кришка; 2, 3, 6 – патрубки; 4 – гайка; 5 – паровий колектор; 7 – вал; 8 – форсунка; 9 – шнек; 10 – корпус; 11 – передня кришка; 12 – лоток
Технічна характеристика теромокоагулятора Я6 – ФПК
| Продуктивність, кг/год. | 300 |
| Температура сировини, °С | |
| початкова, не менше | 10 |
| бланшованої | 65 – 90 |
| Тиск пари , МПа, не більше | 0,25 – 0,6 |
| Питома витрата пари, кг на 1 кг сировини | 0,15 |
| Габаритні розміри, мм | 1200х800х1500 |
| Маса, кг | 300 |
Піч ротаційна К7-ФП2-Г (рисунок 6) призначена для запікання м’ясних хлібів, буженини й інших виробів без оболонки. Вона має вигляд термоізольованої циліндричної камери, закріпленої на опорі. Продукт через підйомні двері завантажують у колиски ротора. Ротор приводиться в обертання електродвигуном через редуктор.
Продукт у колисках безперервно переміщується в камері в потоках пароповітряної суміші. Залежно від режиму подавання пароповітряної суміші відбувається підсушування, обсмажування чи варіння продукту. повітря підігрівається пальниками. Для зволоження середовища використовують гостру пару.
Рисунок 6 – Піч ротаційна К7–ФП2–Г:
1 – двері; 2 – редуктор; 3 – електродвигун; 4 – стояк; 5 – вал; 6 – стрижень; 7 – труба; 8 – засувка; 9 – камера; 10 – колиски; 11 – пальники; 12 – опора; 13 – відбивач; 14 – диски; 15 – противага
Технічна характеристика ротаційної печі К7 – ФП2 – Г
| Продуктивність, кг/г | 110 |
| Частота обертання ротора, с-1 | 0,06 |
| Установлена потужність, кВт | 43,55 |
| Займана площа, м2 | 4,7 |
| Маса, кг | 2330 |
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