Shantou production process

Shantou, a distinctive surface-fermented food originating from China, holds a significant place in the daily lives of many people. Traditionally, its production was carried out in family-run workshops, which limited efficiency and output. However, with the growing demand for more efficient and standardized food processing methods, Shantou has seen notable advancements in mechanization, frozen preservation, and quality control in recent years. **Raw Materials** 1. **Flour**: Typically, medium-gluten flour is used. The standard specifications for bread flour in China include: - Refined grade: 25.0–30.0% wet gluten - Stability curve time: ≥ 3.0 minutes - Falling number: ≥ 250 seconds - Ash content: ≤ 0.55–0.70% 2. **Fermentation agents**: Commonly used are pasta yeast, brewer's yeast, instant dry yeast, or fresh yeast. Baking powder can also be used, though it tends to result in a less flavorful product. 3. **Food base**: Soda ash (sodium carbonate) is typically used as the alkaline component. 4. **Water**: Although water quality can affect fermentation, tap water is generally sufficient for most operations. 5. **Sugar**: Used mainly in sweet varieties, sugar content usually ranges between 5% and 10%. 6. **Emulsifiers**: Many producers still avoid using emulsifiers like sodium stearoyl lactylate due to cost or preference for traditional methods. **Process Flow and Formulation** The production of steamed buns involves several fermentation techniques, including surface fermentation, fermented fermentation, and pure yeast fermentation (also known as new fermentation). Surface fermentation is the most commonly practiced method, with the following process flow: **Raw materials → Dough mixing → Fermentation → Neutralization → Molding → Proofing → Steaming → Cooling → Finished product** A basic dough formula includes: - Flour: 100% - Noodle: 10% - Alkali: 0.5% to 0.8% - Water: 45% to 50% **Key Technical Points** 1. **Dough preparation**: About 70% of the flour and most of the water are mixed first using warm water. The mixture is then kneaded in a uniaxial or crank-type mixer for 5 to 10 minutes until the dough becomes smooth, non-sticky, and flexible. It is then placed in a fermentation tank at 30°C. 2. **Fermentation**: Covered with a damp cloth, the dough is left in a room maintained at 26–28°C and 75% humidity for approximately 3 hours. During this time, the dough doubles in volume, develops an even honeycomb structure, and acquires a distinct sour flavor. 3. **Neutralization**: After fermentation, the dough is mixed again in a noodle mixer, and alkali water is gradually added to neutralize the acidity. The remaining flour and water are then incorporated, and the dough is mixed for 10–15 minutes until fully matured. The amount of alkali is adjusted based on experience—too little results in a sour taste, while too much causes discoloration, cracking, and an unpleasant alkaline flavor. 4. **Molding**: A double-roller spiral forming machine is used to divide and round the dough before placing it into the steamer. 5. **Proofing**: The dough is proofed at 40°C and 80% humidity for about 15 minutes. In natural conditions, the time varies between 20–30 minutes depending on the season. 6. **Steaming**: Traditionally, the dough is steamed over boiling water for 30–35 minutes. In industrial settings, steam from a boiler is used, reducing the time to around 25 minutes. 7. **Cooling**: After steaming, the buns are cooled using air blow for 5 minutes or allowed to cool naturally before packaging. With modernization efforts, the production of Shantou has become more efficient and consistent, while still preserving its traditional character and flavor.

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