What is the main process of Ejiao production?

As soon as the solstice of winter arrives, the old glue shop in Bainiantang is busy boiling glue.

Sacrifice the well god, worship the glue god, soak the skin and sell firewood to make a big stove,

Soak donkey skin for seven days and seven nights, shave, remove fat and dirt,

Cut into pieces and put them in a golden basin. Sang Mu must be used to boil the glue.

The golden pot shoveled silver well water and cooked it for nine days and nights.

Pick firewood in 998 1 year and water in 8864,

The glue is thick, take out the skin slices, and then put them in a golden pot to cook.

The golden pot turns nine, and the silver shovel keeps turning.

Kuya glue is made in nine days and concentrated in nine pots.

Mixing and concentrating, adding wine, sugar and soybean oil,

When the monkey foam is hung and the flag is hung, the paste gel is collected into the ice room.

There is a unique way to decompose the rubber block, and there is no trace after the knife is opened.

Dry the glue for three days, then change the bed after wiping the water.

Then dry the tile box again and turn over the glue twelve times a day.

Seven glue shops take turns to live, and the glue takes 49 days.

Select qualified products, wipe the offset printing before leaving the factory,

Real destiny, natural rubber bath, fire and water, elixir of life,

The combination of yin and yang leads to eternal life, flesh and blood,

Chinese medicine is a thousand-year-old fragrance, and Ejiao is a century-old hall.

This folk song is about the production technology of Ejiao in Dong 'e. It has been a consistent principle for more than 2500 years that Dong 'e Daodi Ejiao chooses good materials and glue. In the production, you can also let a pot boil water all the time, and finally you can boil the glue. But centennial hall abides by the old glue-making method. The traditional technological process of making donkey-hide gelatin in Bainiantang is as follows: after seven days and seven nights, 7749 links and 9981 procedures, the copper pot and silver shovel and Sang Mu are used as firewood, and each key procedure is well controlled to finally achieve first-class donkey-hide gelatin. This is the so-called "heroes in troubled times, Ejiao cures fire and water."

Glue making pays attention to transition and coupling for every process in the middle. This is similar to writing a swan song and composing a famous song handed down from ancient times. Because, Bai Niantang believes that as long as one process goes wrong, the whole dish will be wasted, and the last one will definitely not be good glue.

Every glue-making process in Bainiantang is almost harsh. Bainiantang people adhere to the ancestral motto of "follow the ancient teachings, forget about profit and righteousness, be upright, seek genuine products, avoid shoddy work, and be genuine glue", adhere to the teaching motto of "sincere heart, antique style, leather is genuine, glue is genuine glue, and the price is real, it must be genuine glue", and follow the principle of "refining the holy medicine" to clarify the medicinal properties of Ejiao. The motto of "Doctors are kind-hearted, and medicine is abstinent from cheating" just reflects a scientific craftsman spirit. Centennial Hall has inherited the essence of Ejiao culture for more than 2,500 years.

According to Zhang Chuanfu of Bainiantang, there are 49 ancient repair techniques for Ejiao, including soaking, shaving, blanching, peeling, juice making, foaming, filtering, precipitation, glue discharging, glue cutting, dry glue transfer and glue wiping. According to the ancient method, Ejiao production is very particular about:

The first is to prepare materials. We must take the skin of the "medicine donkey" who eats Twelve Mountains and drinks langxi River, thinking that "medicine donkey" means "eating Adenophora adenophora, Lycium barbarum and asparagus, drinking all mineral water and pulling all kinds of tonics". This kind of skin is the key to making glue.

Followed by bubble skin. Zhang Chuanfu said: "Jin Shao, a native of Yin Shan, Zhejiang Province (now Shaoxing) in the Qing Dynasty, said in the book On Towels and Boxes: The method of making Ejiao is to take the skin and soak it in the river in January in winter, scrape it clean and wash it. Then transport it back to the workshop for cutting and cooking. " What the book says is unscientific, which may be recorded by hearsay-isn't the leather soaked for a month?

Dong 'e Daodi Ejiao's traditional bubble skin making method is generally three days and three nights to four days and four nights, not more than seven days and seven nights. As long as the skin is swollen, the hair on the skin can be pulled off by hand.

The third step is shaving. Put the "soaked" donkey skin on the wooden stool, first remove the carrion and fat inside, and then scrape the surface hair; Teacher Jin said that "it should be transported back to the workshop for cutting and cooking" is also wrong. It's not right to send it back to the workshop for shaving, and the donkey hair has to be washed after shaving. How troublesome it is to transport it back. We used to build a shed on the spot, put up a stake and start working.

The old rubber worker in Bainiantang often said that "only half or two-thirds of the hair is enough", but unlike killing pigs, the skin is scraped clean, and the rubber yield of completely hairless skin cannot go up. According to the current scientific theory, the protein content in hair follicles is very rich, and this kind of protein can be boiled out. In addition, the leather is not pulled back to the workshop immediately after scraping, and there is another process, that is, soaking the leather again, then soaking it in the river for 2-3 days, and then transporting it back to the rubber workshop for cutting.

Step four, cut the skin. Also known as peeling, the old rubber worker of Bainiantang said that after peeling and soaking for 2-3 days, it should be transported back to the workshop for peeling. The key point of skin cutting is to cut the unhairing donkey skin into a square with a width of about 40cm.

Step 5: Wash your skin. Wash the cut skin again, that is, pour the skin into the skin washing pool, and then rinse it back and forth, repeating 7- 10 times.

Bleach the skin. (Chuo, second sound) Put the cleaned donkey skin into the pot, add water, heat it, rinse it, and take it out and fry it.

Step seven, peeling. That is, fried glue. First, the craftsman puts the bamboo basket dedicated to glue boiling into a copper pot, then pours the processed donkey skin onto the bamboo basket, adds water to cover the skin, and heats it with slow fire to keep it slightly boiling 1-2 days.

Zhang Chuanfu of Centennial Hall explained why bamboo baskets should be added. Because it is a bamboo basket, it can avoid the high temperature at the bottom of the pot, scorching the skin and affecting the quality. In this process, the most traditional method is to take out the uncooked skin and cook it in another pot before the glue thickens, and mark the cooked glue which pot it is.

Zhang Chuanfu said: "In this process, Mr. Liu Lao in the Ming Dynasty recorded that if the skin has melted into the water, one bite will be reduced every day, and those who are extremely melted will stop eating one bite, and then put it on the shelf and let it go. Every four days and nights, the glue becomes. "

Of course, boiling glue in a small workshop is not that complicated. They usually boil the glue until it is thick, then pour out the soup, add water and cook it for 3-5 times until the skin is completely melted and the glue is completely fried.

Zhang Chuanfu introduced that peeling has five keys:

1, water addition is very important. The best way to add water is to submerge the skin and keep the pot in a slightly boiling state with bubbles.

2. Fire control is very important. When extracting, heat it with strong fire until it boils, then control the heat and simmer it with low fire, as long as the pot is slightly boiling. In this way, the impurities in the glue can easily float to the upper water surface, and can be wiped when the impurities gather from the edge of the pot to the center.

3. Replenishing water is very important. In order to fry the glue juice in raw materials as much as possible, besides maintaining the temperature and sufficient moisture, it is necessary to replenish the moisture lost by evaporation at any time during the heating and extraction process, so as not to affect the frying of the glue juice due to insufficient moisture.

4. Decocting time is also extremely important. The boiling time is generally 8-48 hours, and it is repeatedly boiled for 3-5 times until there is almost no glue in the boiled glue.

5. every time you fry the glue, you should filter it while it is hot, otherwise it will be difficult to filter it because of its high viscosity after cooling.

Step 8, extract the foam. Also known as foaming, when the glue solution reaches an appropriate concentration, add an appropriate amount of cold water, dilute it, boil it with strong fire, and then slowly heat it with slow fire to make the impurities in the glue solution float to the surface. When impurities gather from the edge of the pot to the center, take them out with a foam spoon or a foam knife. This operation is called "Foam One". Usually soak one in an hour or so. The water used for wiping is very particular, and the well water of Gu 'a Well in Yangcheng, Yanggu must be used.

Zhang Chuanfu of Bainiantang introduced that the most important process in boiling glue is foaming, which is the process of removing impurities from donkey skin. When foaming, add Ajing water back and forth, because Ajing water has a large proportion and there are many minerals in the water. These minerals can easily combine with donkey skin to form a complex to float, and it is easy to remove unnecessary impurities from donkey-hide gelatin. However, water in Jam is extremely rare. The rubber workshops in Old Dong 'e and New Dong 'e are more than 30 kilometers away from Acheng, and New Dong 'e is more than 50 kilometers away from Acheng, so it is difficult to carry water.

The ninth step is filtering. That is to say, every time the glue is boiled, it is filtered with a fine sieve first, and then filtered with silk cotton.

The tenth step is clarification. After filtering, add an appropriate amount of alum into the glue juice, stir and mix evenly, let stand for precipitation, and then filter.

Zhang Chuanfu of Bainiantang said: Because of the high viscosity of glue juice, the impurities contained in it are not easy to settle, so sedimentation or sedimentation and filtration are often used. Generally, an appropriate amount of alum (60-90g alum/100kg raw material, even 120g alum) is added to the glue solution, and it is stirred and left standing for several hours. After fine impurities are precipitated, separate the upper clear glue solution, or filter it with a fine sieve or silk wool, and then put it in a pot and concentrate it with slow fire.

The eleventh is concentration. After filtration and clarification, the glue solutions were combined and concentrated.

Zhang Chuanfu of Bainiantang introduced: This job is to concentrate the filtered glue into syrup, then take it out and let it stand for 24 hours. When the precipitation drops fall behind, pour out the supernatant, put the clarified glue into a copper pot, heat it with slow fire, concentrate and foam, and foam it about 1 hour. In the meantime, stirring should be continued to prevent coking. When it reaches a certain concentration, impurities are removed, and the glue cannot penetrate through the paper, rock sugar can be added, and then it is continuously concentrated after stirring until it is completely dissolved.

The old rubber worker of Bainiantang also said: "Concentrate on collecting rubber, the firepower should not be too big, and it should be constantly stirred. If there is foam, it should be removed in time. With the continuous evaporation of water, the viscosity of glue solution is getting bigger and bigger, so it is necessary to prevent coking.

Step 12, hang beads. The function of hanging beads is to judge the water content of glue solution according to the flow rate of glue solution. The so-called bead hanging means that after the glue is concentrated to a certain extent, it is lifted with a glue shovel and the glue slowly flows down in the shape of beads. Add soybean oil at this time.

Step 13, smash oil. After adding soybean oil to the hanging beads, the oil should be "mashed", that is, after adding oil to the glue solution, scoop up the glue solution with oil with a glue spoon, then pound it into the pot and mix it with the glue solution in the pot. At this time, the glue solution is stirred vigorously, so that the oil and the glue solution are fully mixed, and the oil is evenly dispersed to avoid small oil bubbles in the glue.

Step 14, hang the monkey. When the glue solution is concentrated to a certain extent until it approaches the glue solution, start to "hang the monkey" (lift it with a glue shovel, and the glue solution hangs on the glue shovel like a monkey), and add yellow wine while stirring. At this time, the fire should be weakened and vigorously stirred to promote water evaporation and prevent coking.

Step 15, make a pot. Concentrate the glue solution to a certain concentration, add auxiliary materials, and heat it with slow fire for a period of time, so that steamed bread-like bubbles bulge on the surface of the glue solution, commonly known as "boiling pot". At this time, the heating of the glue solution should be stopped to make the bubbles in the glue solution evaporate naturally.

Step 16, sober up. It's time to "sober up" when it's "boiling". The phenomenon of "foaming" in the glue pot means that the glue will come out, so that the hot air in the pot will naturally escape, so that there will be no oil bubbles and gas bubbles in the glue solution. This process is called "sober up".

Step 17: Hang the national flag. Also known as shovel. When the glue is concentrated to a certain degree, shovel it with a glue shovel, and the glue sticks to the shovel, showing a sheet shape and slowly falling. Lift the shovel, collect the glue, pour the glue into the gel plate and naturally coagulate to get the gel.

When the glue is stirred up, it will stick to the stick in sheet form without falling off (also called hanging the flag), and the glue will be concentrated until no water vapor escapes. The degree of concentration should be properly controlled, because there is too much water, and the finished product often collapses during drying.

18. Gelation: After the glue solution is melted, it is poured into the gel plate while it is hot, and naturally coagulates, so that the glue solution solidifies into a large glue block. This process is called gelation.

After the Ejiao is cooked. Pour it into a gel plate coated with vegetable oil while it is hot, and let the glue naturally solidify into a ball. Before gel, wash the gel plate, dry it, apply a small amount of sesame oil or soybean oil, pour it into hot glue solution and put it indoors (cold dew-produced in Grain Rain). 12 ~ 24 hours later, it can be solidified into gel block. After the glue is solidified, it can be cut into small pieces of specified specifications.

Step 19: Open the film. After gelation, it is to open the sheet and seal the glue. Concentrate the glue solution to obtain a glue mass, and cut the glue mass into small pieces of specified specifications with a knife to obtain a plastic film. This process is commonly known as "membrane opening".

Bai Niantang's old rubber worker emphasized that manual operation needs a flat knife edge and a one-size-fits-all approach to prevent knife marks.

Step 20: Dry in a cool room. After cutting the film, put it in the glue drying room, dry it in the shade on the bakelite bed for a few days, and then put the opened small pieces of glue neatly in a wooden box and seal it tightly. This process is called glue sealing, also called "glue tile box". Its purpose is to make the moisture inside the film diffuse outward, so as to narrow the moisture difference inside and outside the film and play a role in shaping.

Dry the cut film in the shade, seal the film (including tile box, vertical box, inverted box and sealed box), air dry the film, wipe the film, print, sterilize, seal the film (wrap small pieces, box, label, wrap large skins, box, seal the box), inspect and package.

Step 2 1: dry the glue in the drying room. After 3 ~ 5 days, it is transferred to a bamboo curtain bed, placed in a drying room in layers, and dried in a cool condition. Generally, the glue is turned once every 3 ~ 5 days, so that the water on both sides is evenly distributed and the finished product is prevented from bending.

Step twenty-two, stuffy glue. After a few days, when the adhesive surface is dried to a certain extent, it is sealed in a wooden box to make the moisture of the film diffuse outward, which is called "sealing glue" or "covering glue" or "tile glue".

Step 23: Turn the box upside down and erect it. In the process of blocking glue, we should also constantly pour boxes and erect boxes.

Step 24: After drying the water for 2-3 days, take out the film and wipe off the water on the surface with a cloth, and then put it in a glue drying room with a bamboo curtain for drying at a higher temperature.

Step 25: Dry the glue in the drying room. After a few days, put the film in a wooden box and seal it for 2-3 days.

Repeat this operation for 3 ~ 4 times to achieve the purpose of drying.

Step 26, rub the glue. After the film is fully dried, use coarse cloth to take glue (glue: first heat the water to boiling, and then cool it to a suitable temperature) to wipe its surface, so that the six sides of the film are bright and shiny, with straight and obvious coarse cloth texture.

Step 27, print. Printing product names with silver beads

Step 28, packaging.

Step 29, check. Store in a sealed container in a cool and dry place to prevent moisture, heat, mildew, softening, adhesion and deterioration; But the film should not be too dry, so as not to break the film.

This ancient method of repairing Ejiao is a layer-by-layer transformation. One careless move will lose the game. Little donkey skin made an article about the doctor, which is really not easy to correct.