(1) Shelling: To remove the chestnut shells, either use artificial shelling methods or a mechanical sheller. Before shelling, it's essential to expose the chestnuts to heat for 6 to 8 hours at a medium temperature of 70–80°C, or bake them at 150–180°C for 20–25 seconds to allow the shells to crack naturally. It’s crucial to carefully control both temperature and time, as improper conditions can cause the chestnuts to brown after peeling. During the shelling process, any machinery that comes into direct contact with the chestnuts should be made of stainless steel to maintain hygiene and prevent contamination.
(2) Dehusking and Color Protection: After shelling, place the chestnuts into a 6% to 8% sodium hydroxide solution at a temperature of 90–95°C for 2–3 minutes. The amount of solution should be about two to three times the weight of the chestnuts. This step helps in deactivating enzymes on the surface. Immediately after, rinse the chestnuts thoroughly with clean water. Then, treat them with a 2% to 4% dilute hydrochloric acid solution for 4–6 minutes to neutralize any remaining alkali. Finally, wash the chestnuts with a solution containing 0.1% citric acid, followed by a color protection treatment using a 0.1% sodium chloride and 0.05% EDTA-2Na solution to preserve the natural color.
(3) Pre-cooking: After the color protection treatment, transfer the chestnuts into a pre-cooking solution consisting of 10% sucrose, 0.1% sodium chloride, 0.1% EDTA-2Na, and 0.1% citric acid. Cook for 40 minutes, maintaining a liquid-to-chestnut ratio of 2:1.
(4) Syrup Preparation: Prepare a mixed syrup using a ratio of 5 parts sucrose, 2 parts maltose, and 3 parts liquid glucose syrup. Dissolve 100 kg of sucrose in 50 kg of water, then add the maltose and liquid glucose. Heat the mixture until it reaches boiling point, and maintain it at 85°C for 10 minutes to ensure proper dissolution.
(5) Grinding: After cooking, pass the chestnuts through a sieve with a 0.2 mm diameter to obtain a fine slurry. Further grind the mixture using a colloid mill, and transfer the resulting paste to a mixing tank for subsequent processing.
(6) Product Formulation: Weigh 5% milk powder, 0.005% ethyl maltol, and 0.35% xanthan gum based on the final product weight. Mix these ingredients with heated water and pump the mixture into a mixing tank. Add 10% chestnut pulp and adjust the total volume with water. Homogenize the mixture using a high-pressure homogenizer at 17.64–21.56 MPa to ensure a smooth texture.
(7) Final Processing: Before filling, perform vacuum degassing at a temperature of 35–45°C, a vacuum level of 90–96 kPa, and for a duration of 10 minutes to prevent oxidation. After degassing, quickly sterilize the product at a high temperature and immediately fill it using a continuous automatic packaging machine. Once filled, the product is inspected and then ready for distribution.
The finished product has a pale yellow color, a unique chestnut aroma, a balanced sweetness, a rich mouthfeel, and no signs of sedimentation or layering. This method ensures a high-quality, stable, and flavorful chestnut-based milk drink.
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