A processing technology for preparing soft tobacco based on the adhesion characteristics of tobacco leaves

Abstract

The present application relates to a kind of processing technology based on softness better tobacco processing of tobacco adhesion characteristics, according to small leaf group preset proportion, different regions, different proportion requirements of tobacco are stored into designated area of leaf selection workshop for standby;Leaf selection, leaf blending, leaf re-drying and silk making.This technical scheme carries out raw material grouping and leaf beating according to adhesion force combined with tobacco grading standard, and the sheet rate and quality consistency of tobacco are better, which is more beneficial to produce higher softness tobacco.This technical scheme finds out the relationship between cigarette rolling quality and tobacco softness, establishes a set of processing technology and parameters that can improve the flexibility of tobacco, and the produced tobacco is better in softness;The tobacco made by the present application has good rolling applicability, low air head rejection rate and relatively low process consumption during rolling process;After rolling, the physical indexes of cigarette are stable, and the product quality is more stable.

Description

Technical Field

[0001] This invention belongs to the field of tobacco processing technology, specifically relating to a processing technology for producing softer tobacco shreds based on the adhesive properties of tobacco leaves. Background Technology

[0002] During the production process, it is often found that different batches of tobacco produced with the same brand, formula, and standard have no significant differences in the test results of quality indicators (moisture content, filling value, tobacco structure). However, during the rolling process, there are often significant differences in the performance of the tobacco in terms of quality indicators (empty ends, suction resistance, end-dropping, etc.), equipment efficiency (running, stopping, etc.), and process losses (removal of unqualified tobacco sticks), as shown in Tables 1 and 2.

[0003] Table 1. Results of physical indicators for cigarettes with different tobacco softness

[0004]

[0005]

[0006] Table 2 Correlation between tobacco softness and cigarette physical indicators

[0007]

[0008]

[0009] The reason for this is that the existing physical property indicators of tobacco shreds are not perfect enough and cannot fully and accurately reflect the quality of tobacco shreds. In production, it has been found that the softness of tobacco shreds is closely related to the physical quality of tobacco shreds and the rolling effect. Tobacco shreds with the same whole shred rate, elasticity, filling value and other indicators are more suitable for tobacco shred rolling when the tobacco shreds are soft. The physical indicators of rolled cigarettes are stable. However, the adhesion of tobacco leaves from the same place of origin but different grades is significantly different, and the softness of the processed tobacco shreds is also quite different. Summary of the Invention

[0010] The purpose of this invention is to provide a processing technology for producing softer tobacco shreds based on the adhesive properties of tobacco leaves, in order to solve the problem that there are often significant differences in the performance of tobacco shreds in terms of quality indicators, equipment efficiency, and process losses during the rolling process.

[0011] To achieve the above objectives, this application employs the following technical solution:

[0012] A processing technique for producing softer tobacco shreds based on the adhesive properties of tobacco leaves includes the following steps:

[0013] S1. According to the preset ratio of small leaf groups, tobacco leaves from different regions and with different ratio requirements are stored in the designated area of ​​the leaf selection workshop for later use.

[0014] S2. Leaf selection: Select single-grade tobacco leaves from the small leaf group in step S1 according to the following steps.

[0015] S21. Select representative tobacco leaf samples of different colors and maturity levels from this single grade of tobacco leaves, seal them for later use.

[0016] S22. A set number of tobacco leaf graders evaluate the representativeness of the tobacco leaf samples in step S21, confirm their representativeness, and designate representative samples.

[0017] S23. After the representative sample from step S22 is equilibrated at 20±2℃ and 75±5% humidity for 48 hours, its adhesion force is tested.

[0018] S24. Analyze the detection data from step S23 and formulate the selection of cigarette standard samples;

[0019] S25. Select tobacco leaves according to the tobacco sample in step S24, and classify, store and process the selected tobacco leaves for future use.

[0020] S3. Leaf preparation: Prepare leaves according to the formula requirements;

[0021] S4. After the tobacco leaves were mixed in step S3, the leaves were threshed and re-dried.

[0022] S5. Process according to the existing filament-making process, and adopt thin-cutting and thin-plate drying process during the filament-making process, wherein the filament width of the thin-cutting process is 0.8 to 1.0 mm.

[0023] Furthermore, in step S23, the adhesion force is determined by measuring the tobacco leaf adhesion force using a texture analyzer.

[0024] Furthermore, in step S24, the tobacco standard sample is selected according to the region, part, grade and adhesion comparison table of the tobacco leaf.

[0025] Furthermore, in step S25, leaf selection is carried out manually or mechanically. Manual leaf selection involves training tobacco selectors to master tobacco selection standards, identify standard samples, and select leaves. Mechanical leaf selection involves collecting standard sample feature data and inputting it into an automatic leaf selection system, using image recognition methods to select leaves.

[0026] Furthermore, in step S25, impurities and dregs in the tobacco leaves are removed by manual or mechanical leaf selection.

[0027] Furthermore, the leaf re-baking in step S4 is performed as follows:

[0028] S41. After the second leaf-moistening process, the tobacco leaf adhesion is above 1100g, the outlet moisture content is 16.0% to 18.0%, and the outlet temperature is 60.0% to 65.0℃.

[0029] S42. After the second leaf-moistening process, the tobacco leaves are threshed and air-separated.

[0030] S43. The first set time for storing tobacco leaves after leaf threshing and air separation.

[0031] S44, Step S43: The tobacco leaves after storage are re-dried;

[0032] S45. The re-dried tobacco leaves are stored again to balance the moisture and temperature of the tobacco leaves.

[0033] S46, The second set time for the natural aging of the re-baked tobacco sheets.

[0034] Furthermore, the first set time is no less than 50 minutes, and the second set time is 2.5 to 3 years.

[0035] Furthermore, in step S45, the moisture content of the tobacco leaves after equilibration is controlled between 12.0% and 12.5%, the temperature is not higher than 28°C, and the adhesion of the tobacco leaves is not higher than 1150g.

[0036] The beneficial effects of this invention are:

[0037] 1. This technical solution proposes a method for leaf selection based on adhesion force, which is more objective, easier to quantify, and facilitates the verification of leaf selection qualification rate.

[0038] 2. By grouping and pounding raw materials according to adhesion and tobacco grading standards, the yield and quality consistency of tobacco leaves are better, which is more conducive to producing tobacco leaves with higher softness.

[0039] 3. Through research, the relationship between cigarette rolling quality and tobacco softness was identified, and a set of processing techniques and parameters that can improve the softness of tobacco were established, resulting in tobacco with better softness.

[0040] 4. The tobacco shreds produced using this invention have good rolling suitability, a low rate of empty end removal during the rolling process, and relatively low process consumption; the physical properties of the rolled cigarettes are stable, resulting in more consistent product quality. Detailed Implementation

[0041] The technical solutions of the present invention will be described in detail below with reference to the embodiments. The following embodiments are merely exemplary and can only be used to explain and illustrate the technical solutions of the present invention, and should not be construed as limiting the technical solutions of the present invention.

[0042] This application provides a processing technology for producing softer tobacco shreds based on the adhesive properties of tobacco leaves, including the following steps:

[0043] 1. Material preparation: According to the preset ratio of small leaf group, tobacco leaves from different regions and with different ratio requirements are stored in the designated area of ​​the leaf sorting workshop for later use.

[0044] 2. Leaf Selection: Because the incoming tobacco leaves after threshing and re-drying contain a large amount of leaves from other parts of the plant, unripe leaves, and other non-compliant materials such as chicken feathers and hemp rope, the pass rate for grade acquisition is generally below 60%. Therefore, the tobacco leaves need to be selected and graded to improve their purity and usability. However, due to differences in the visual perception of raw material graders and significant discrepancies between the industrial usability requirements and the 42-grade grading standard for tobacco leaves, the grading of the same leaf often results in significant discrepancies in judgment. Therefore, a combination of quantitative and qualitative methods is used to develop standard samples and select leaves. Since a single grade of tobacco leaf contains leaves from different parts of the plant, their quality and adhesion vary considerably. The adhesion of tobacco leaves is strongly positively correlated with their grade, color, and maturity. The adhesion of a single grade of tobacco leaf is tested to determine its corresponding color and maturity, which serves as the standard sample for selection. The specific operating steps are as follows.

[0045] (1) Select 30 representative tobacco leaf samples of different colors and maturity from the single grade, seal them in plastic bags and set aside.

[0046] (2) The representativeness of the sample is evaluated by a number of tobacco graders to confirm its representativeness and to formulate the sample.

[0047] (3) The representative tobacco leaves confirmed by the grader were equilibrated for 48 hours at 20±2℃ and 75±5% humidity and then their adhesion was tested. The adhesion was determined by the texture analyzer method.

[0048] (4) Analyze the test data and formulate standard samples for tobacco selection. Select standard samples according to the comparison table of tobacco leaf region, part, grade and adhesion force listed in Table 3 as the basis for leaf selection (F is adhesion force).

[0049] Table 3. Comparison of tobacco leaf region, part, grade, and adhesion force: F represents adhesion force, unit: g.

[0050] sample upper part Central lower part Henan 400≤F 660≤F 440≤F Yunnan 600≤F 750≤F 700≤F Sichuan 420≤F 670≤F 460≤F Hunan 450≤F 680≤F 500≤F EFujian 500≤F 700≤F 650≤F Northeast F 450≤F 600≤F 400≤F G Chongqing 430≤F 670≤F 460≤F H Hubei 480≤F 700≤F 550≤F

[0051] (5) Train tobacco selectors to master tobacco selection standards, identify standard samples and select leaves; or use image recognition to select leaves, collect standard sample feature data and enter it into the automatic leaf selection system; at the same time, use manual or machine leaf selection to remove impurities, lees and other debris from tobacco leaves.

[0052] (6) Selected tobacco leaves are classified, stored, and processed for future use.

[0053] 3. Leaf preparation: Prepare leaves according to the formula requirements on the mixing table.

[0054] 4. After leaf blending, the tobacco leaves undergo threshing and re-curing:

[0055] (1) After the second moistening process, the adhesion of the tobacco leaves should reach more than 1100g. At this time, the moisture content at the outlet is 16.0% to 18.0%, and the outlet temperature is 60.0% to 65.0℃.

[0056] (2) After the second processing, the tobacco leaves are threshed and air-separated.

[0057] (3) After the tobacco leaves are blown and separated, they are stored for no less than 50 minutes. By appropriately extending the storage time, the difference in moisture between the surface and the inside of the tobacco leaves is balanced, so as to balance the moisture of the tobacco leaves, solve the problem of "crispy on the outside and tender on the inside" of the tobacco leaves, reduce the breakage of the tobacco leaves in subsequent processing, and improve the uniformity of moisture transfer during the drying process.

[0058] (4) After storing the tobacco leaves, the tobacco leaves are re-dried. The process parameters and quality indicators of the re-drying process shall be implemented in accordance with the current conventional process requirements.

[0059] (5) The re-dried tobacco leaves are stored again to balance the moisture and temperature of the tobacco leaves. The experiment shows that after balancing, the moisture content of the tobacco leaves is controlled between 12.0 and 12.5%, the temperature is not higher than 28℃, and the adhesion of the tobacco leaves is not higher than 1150g. The tobacco leaves are less likely to produce oil, caking and mold during packing and natural aging.

[0060] (6) After re-drying, the tobacco leaves are packaged and sent to the warehouse for natural aging for 2.5 to 3 years. At this time, the quality and adhesion of the tobacco leaves reach a good state and meet the formula adjustment cycle. Natural aging can promote material transformation and improve the quality of tobacco leaves. On the other hand, natural aging can improve the maturity of tobacco leaves, thereby improving the softness and oil content of tobacco leaves.

[0061] 5. Silk production:

[0062] (1) The silk processing is carried out according to the existing silk processing technology, including the following steps: material preparation, slicing, vacuum rehydration, loose rehydration, adding materials to leaves or filaments, drying of leaves and filaments, adding fragrance, and storing silk.

[0063] ① Thin-cutting process is adopted: As shown in Table 4, as the width of the shredded tobacco increases, the softness index value increases and the softness decreases. However, when the width of the tobacco shreds is too narrow, the tobacco structure is poor and the loss is large. When the width of the tobacco shreds is too wide, the proportion of long filaments is high, the rationality of the tobacco structure is poor, and the stability of the quality index of the rolled cigarettes is poor. The appropriate shredded tobacco width is between 0.8 and 1.0 mm.

[0064] Table 4. Tests on the softness of tobacco shreds with different shred widths.

[0065]

[0066] ② Thin-plate drying process was adopted. As shown in Table 5, for a certain product, the shred width was set to 0.8mm, 0.9mm, and 1.0mm respectively. Thin-plate drying and airflow drying methods were used respectively, and the softness of the dried tobacco shreds was tested, as shown in Table 5. The softness values ​​were ranked as follows: airflow drying > thin-plate drying. The tobacco shreds dried using thin-plate drying had the lowest softness value and the best softness.

[0067] Table 5. Tests on the softness of tobacco shreds under different drying methods.

[0068]

[0069] Example 1

[0070] Taking one of the Yunnan leaf group modules used in the above formula as an example, as shown in Table 6. The assembly and processing of small leaf group modules from other regions such as Henan and Fujian are similar to this example. The proportion of tobacco leaves of each grade in the Yunnan leaf group module is shown in Table 6.

[0071] 1. Selecting leaves:

[0072] Taking the Yunnan leaf module as an example, it is a typical light-aroma module with an elegant and sweet fragrance, a sufficient amount of aroma, high smoke concentration and strength, and a clean aftertaste. It is used in high-end cigarette products as a flavoring raw material.

[0073] Table 6. Proportion of different grades of tobacco leaves in Yunnan leaf group module

[0074] Serial Number years area grade Proportion% 1 2022 Lincang B3F 30 2 2022 Chuxiong B2F 30 3 2022 Lijiang X2F 10 4 2022 Wenshan B2F 30

[0075] (1) Material preparation: Prepare materials according to the formula requirements of module 6 in Table 6.

[0076] (2) Select leaves:

[0077] Sampling: First, the tobacco selection supervisors and tobacco graders in the workshop will jointly sample the tobacco leaves. From the four types of tobacco leaves required in Table 6, five stacks of tobacco leaves will be randomly selected, one bundle from each stack, and five bunches from each bundle, with about 7-8 leaves per bunch. These will be sealed in plastic bags and sent to the tobacco selection laboratory with standard light source for preparation and balancing.

[0078] Standard Sampling: Tobacco leaf graders and supervisors grade the collected samples in the laboratory to grade them and initially establish standard samples for tobacco selection. The adhesion of the initial standard samples is tested, and the standard samples are screened based on the adhesion. The test data are compared with Table 3. Samples that meet the requirements of Table 3 are used as standard samples, and those that do not meet the requirements of Table 3 are discarded.

[0079] (3) Train tobacco selectors to master tobacco selection standards, identify standard samples, and select leaves; at the same time, use manual or machine leaf selection methods to remove impurities, lees, etc. from the tobacco leaves. Inspectors randomly inspect the selected samples, test their adhesion, and determine their pass rate, providing a basis for assessment or whether rework is required.

[0080] (4) Selected tobacco leaves are weighed and packaged, each package weighing 50kg, and then stored, stored, and disposed of according to their classification.

[0081] 2. Remove leaves and re-dry:

[0082] (1) Leaf blending: Blend the leaves on the blending table according to the formula requirements in Table 6, ensuring that different tobacco leaves are evenly placed on the blending table.

[0083] (2) Cutting: Perform cutting process to remove the leaf base.

[0084] (3) First moistening: The tobacco leaves with the leaf base removed are sent to the first moistening process to moisten the leaves, which increases the moisture content and processing resistance of the tobacco leaves. The moisture content at the outlet is 15±1%.

[0085] (3) Second humidification: After the first humidification, the tobacco leaves are humidified again, with the outlet moisture content at 16.5±1% and the outlet temperature at 63.0℃.

[0086] (4) Leaf threshing and air separation: The tobacco leaves after the second processing are threshed and air separated.

[0087] (5) Leaf storage: Leaf storage time is 60 minutes.

[0088] (6) Re-drying: The moisture content of the tobacco leaves after re-drying is 12.0±0.5%.

[0089] (8) Leaf storage: Leaf storage time is 30 minutes.

[0090] (9) Packing: The packing weight is 200kg.

[0091] (10) Maturation: Send to warehouse for natural aging for 2.5 to 3 years.

[0092] 3. Silk production:

[0093] (1) Add ingredients according to the product formula requirements.

[0094] (2) The silk is processed according to the existing silk making process, including slicing, vacuum rehydration, loose rehydration, adding leaves or leaf filaments, drying leaf filaments, adding fragrance, and storing silk. Among them, the width of the slicing is 0.8 mm; the thin plate drying process is adopted, and the moisture content after drying is 12.8 ± 0.5%.

[0095] 4. Roll packaging

[0096] The tobacco shreds were pneumatically rolled, and samples were taken for comparison with the quality indicators of cigarettes of the same grade, as shown in Table 7. All quality indicators were significantly better than the comparison products, and the rate of rejecting empty ends was significantly reduced.

[0097] Table 7. Results of physical indicators for cigarettes with different tobacco softness

[0098]

[0099] The above-described embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A process for producing a tobacco shred having a good softness based on the adhesion properties of tobacco leaves, characterized in that, It comprises the following steps: S1, according to the proportion of the leaflet group, store the tobacco leaves of different regions and different proportion requirements in the designated area of the leaf selection workshop for standby; S2, leaf selection, for single grade tobacco leaves in the leaflet group in step S1, leaf selection is carried out according to the following steps; S21, select tobacco leaf samples with different color and maturity in the single grade tobacco leaves, and seal them for standby; S22, the representative of the tobacco leaf samples in step S21 is evaluated by a certain number of tobacco graders, and the representative sample is confirmed and formulated; S23, the representative sample in step S22 is detected for its adhesion after being balanced for 48 hours under the condition of 20±2℃ and humidity of 75±5%; S24, analyze the detection data of step S23 and formulate the selected tobacco standard sample; S25, select leaves according to the selected tobacco standard sample in step S24, and store, standby and process the selected tobacco leaves; S3, leaf blending, according to the requirements of the formula; S4, the tobacco leaves after leaf blending in step S3 are processed by leaf threshing and redrying; S5, according to the existing silk making process, thin cutting and thin plate drying process are adopted in the silk making process, wherein the cutting width of the thin cutting process is 0.8-1.0mm; The leaf threshing and redrying in step S4 is carried out according to the following steps: S41, after the second leaf moistening process, the adhesion of the tobacco leaves is above 1100g, at this time, the outlet moisture is 16.0%-18.0%, and the outlet temperature is 60.0-65.0℃; S42, after the second leaf moistening process, the tobacco leaves are threshed and separated by air; S43, the tobacco leaves after threshing and air separation are stored for a first set time; S44, the tobacco leaves after storage in step S43 are redried; S45, the redried tobacco leaves are stored again to balance the moisture and temperature of the tobacco leaves; S46, the redried tobacco sheets are naturally aged for a second set time; The first set time is not less than 50 minutes, and the second set time is 2.5-3 years; In step S45, the moisture of the balanced tobacco leaves is controlled between 12.0-12.5%, the temperature is not higher than 28℃, and the adhesion of the tobacco leaves is not higher than 1150g.

2. The process for producing soft cut tobacco based on the adhesion characteristics of tobacco leaves according to claim 1, wherein In step S23, the adhesion is measured by the texture analyzer method.

3. The process for producing soft cut tobacco based on the adhesion characteristics of tobacco leaves according to claim 1, wherein In step S24, the selected tobacco standard sample is selected according to the area, position, grade and adhesion of the tobacco leaves.

4. The process for producing soft cut tobacco based on the adhesion characteristics of tobacco leaves according to claim 1, wherein In step S25, manual or mechanical leaf selection is adopted, wherein manual leaf selection is carried out by training the leaf selection personnel to master the leaf selection standard, identify the standard sample and select the leaves, mechanical leaf selection is carried out by collecting and inputting the characteristic data of the standard sample into the automatic leaf selection system, and the image recognition method is adopted to select the leaves.

5. The process for producing soft cut tobacco based on the adhesion characteristics of tobacco leaves as claimed in claim 1, wherein, In step S25, the impurities and bad leaves in the tobacco leaves are removed by manual or mechanical leaf selection.

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