Study On Fabrication Process And Storage-tolerance Of Instant Dumplings

Dumplings are the traditional cuisine of China, and also the world-renowned cuisine. However, the process of making dumplings is so complicated that the common family or the individual does not have the time and strength to make them. Though we have frozen dumplings, the dumplings have to be boiled before being eaten. If we want to have dumplings, we must have stoves, cooking pots, and etc. It will take us much time to cook. In the same time, we can not have them when we are by train, in the office or traveling.In order to fulfill the will that the people can have them whenever or whatever they want to, the instant dumplings is researched. We can eat them after 5~8 minutes immersion in the hot water after opening the wrapper. So it's very convenient.The research work mainly focuses on: the tests of the study of the dumpling formula, the choice of the packaging materials and the determination of the parameters of packing process, the determination of product sterilization process parameters, the research of the anti-aging of the starch, the detections of product's quality target.The main findings are as follows:1. The fixed temporary formula is determined after carrying out the amount of water tests, the addition of salt in flour tests, and the amount of aspic in stuffing tests, the addition of salt in stuffing tests.2. Through the comparison of package materials'advantages and shortages and considering about the product storage conditions and shelf-life, we determined to use the retort pouch as outside package of product. The structure of the retort pouch is 15μm nylon /80μm chlorinated polypropylene. In order to improve the attraction of appearance of products, we decide to use the polypropylene plastic pallets as inside package of product.3. The most suitable parameters of heat sealing of the vacuum packaging machine for sealing bags is determined by single-factor test of heat sealing voltage and heating time. It is: the heat sealing voltage is 36V, the heating time is 9s, and the cooling time is 5s. The vacuum time of the vacuum packaging machine is determined by product vacuum test, which is 12.6s. The corresponding vacuum is -0.075 MPa.4. The means of product sterilization is anti-pressure sterilization, and sterilization temperature is set at 121℃. Through sterilization time single-factor tests, the sterilization time is determined at 25min. In the preservation period simulation tests, the dumplings can be preserved at room temperature for more than 6 months in this sterilization conditions.5. After analyzing the factors that influence the retrogradation of the starch and the anti-aging methods we decide to take molecular distillation monoglyceride (DMG), sucrose fatty acid ester and sodium alginate as the anti-aging agents of the starch. The appropriate addition of the three additives is decided by the addition tests of molecular distillation monoglyceride, sucrose fatty acid ester and sodium alginate respectively. After carrying out an orthogonal test we know that molecular distillation monoglyceride is the most effective and sucrose fatty acid ester is more effective than sodium alginate. The best formula of the composite anti-aging agent of starch is determined by means of the quadratic general rotary unitized design test: molecular distillation monoglyceride (0.86%), sucrose ester (0.8%), sodium alginate (0.46%). According to this formula to add anti-aging agent to the dumpling flour, the dumpling can be preserved for 6 months in normal temperature and the aging degree is 28.2%. Without anti-aging agent, after 6 months preservation in normal temperature, the aging degree is 48.7%. Therefore it comes to the conclusion that adding anti-aging agent in this formula makes a very good anti-aging effect.6. According to the fixed temporary formula and the research of the anti-aging of the starch, the best formula of instant dumplings is as follows: dumpling flour:100g, purified water:50g, salt used in the flour:0.6g, molecular distillation monoglyceride:0.86g, sucrose ester:0.8g, sodium alginate:0.46g, pork :70g, aspic:56g, salt for the stuffing:1.4g, soy sauce:7g, sesame oil:1.4g, fresh ginger:3.5g, scallion:10.5g, Qi Shen tiao xian wang( used for making the stuffing be delicious):0.6g.7. The results of the detections of product's quality target are as follows: the sensory inspected is qualified; the moisture content of dumpling is 64.8%, the protein content of dumpling stuffing is 11.5%, the fat content of the dumpling is 3.3g/100g, the acid value of dumpling stuffing is 0.039mg/g, the peroxide value of dumpling stuffing is 0.0049g/100g; total number of bacterial colony <10 cfu/g, number of coliform bacteria<30 MPN/100g, mold count <10 cfu/g, pathogens (salmonella, shigella, staphylococcus aurous) is not detected; the stuffing content of dumpling is 45.5%.As a new species of convenience food, instant dumplings are not only convenient, but also more nutritious and have more types than other convenience food, which could be able to meet people's demand for hygeian, nutritious, healthful, and convenient. Instant dumplings have enormous consumer population and a broad market prospects, there is no doubt that the instant dumplings will be the most potential product. They can bring good social benefits and very considerable economic benefits.