An automatic blending control method for tobacco concentrate

Abstract

The application belongs to the technical field of tobacco, and particularly relates to a method for real-time adjustment of flow of premixed tobacco leaf extract or tobacco stem extract. The method provided in the application can adjust the flow of the tobacco stem extract and the tobacco leaf extract in real time through real-time detection of the solid content, so as to obtain coating liquid with stable quality, and thus the sensory quality of tobacco smoking is improved.

Description

An automatic preparation and control method for tobacco concentrate Technical Field

[0001] This invention belongs to the field of tobacco technology, and particularly relates to a method for real-time adjustment of the flow rate of premixed tobacco leaf extract or tobacco stem extract. Background Technology

[0002] The reconstituted tobacco production process uses extracts from tobacco stems and leaves. Currently, the extracts used are prepared by extracting, concentrating, and blending tobacco stems and leaves separately. However, the separate extraction and concentration of tobacco stems and leaves is time-consuming, and the waiting time and excessive soaking time of the pulp can affect the stability of the sheet quality.

[0003] The method of mixing and then concentrating extracts from tobacco stems and leaves can significantly reduce the waiting time in the production process. However, this method also has significant problems. Specifically, the solid content of the tobacco stem and leaf extracts is extremely unstable during the production process, and the determination of solid content has a serious lag (the method for determining solid content is to take 10g of extract in a weighing box, dry it in a 100℃ drying oven for 3 hours, remove it and place it in a desiccator, and weigh it after cooling to room temperature; the proportion of the remaining weight to the weighed weight is the solid content. Therefore, it is impossible to determine the solid content at the time of mixing). The fluctuation of solid content leads to fluctuations in the effective components in the mixed tobacco stem and leaf extracts, thus affecting product quality.

[0004] Therefore, there is an urgent need to provide a method that can detect the solid content of tobacco stem extract and tobacco leaf extract in real time and improve the quality stability of the mixture of tobacco stem extract and tobacco leaf extract. Summary of the Invention

[0005] To save time and steps in preparing the coating solution, the inventors first mixed the tobacco stem extract and the tobacco leaf extract and then concentrated them, thus avoiding the time and steps wasted by concentrating the tobacco stem extract and the tobacco leaf extract separately.

[0006] Furthermore, through numerous experiments, the inventors obtained an index (i.e., total sugar) that can accurately characterize the solid content of tobacco stem extract and tobacco leaf extract in real time. This index is particularly suitable for characterizing the solid content of tobacco stem extract and tobacco leaf extract, and is significantly superior to other indexes.

[0007] Finally, the applicant adjusted the flow rates of the tobacco stem extract and tobacco leaf extract in real time by detecting the solid content in real time, so as to obtain a coating liquid with stable quality, thereby improving the sensory quality of tobacco smoking.

[0008] Therefore, this application provides a method for real-time adjustment of the flow rate of premixed tobacco leaf extract or tobacco stem extract, the method comprising:

[0009] (1) Prepare premixed tobacco stem extract and tobacco leaf extract separately;

[0010] (2) The total sugar content of the premixed tobacco stem extract was detected in real time, and the solid content of the tobacco stem extract was calculated by the linear equation y = 0.6376x + 0.081; where x is the solid content of the tobacco stem extract and y is the total sugar content of the tobacco stem extract.

[0011] (3) The total sugar content of the premixed tobacco extract was detected in real time, and the solid content of the tobacco extract was calculated by the linear equation y = 0.8169x + 0.1317; where x is the solid content of the tobacco extract and y is the total sugar content of the tobacco extract.

[0012] (4) Based on the selected tobacco stems and leaves brands, pre-select the stem and leaf solid content formula design ratio T, where T is selected from 30% to 60%;

[0013] (5) Measure the real-time flow rate V_leaf of the tobacco leaf extract and calculate the real-time flow rate of the premixed tobacco stem extract using the formula T×S_leaf×V_leaf÷S_stem; where S_stem is the solid content of the tobacco stem extract obtained in step (2) and S_leaf is the solid content of the tobacco leaf extract obtained in step (3).

[0014] or,

[0015] The real-time flow rate Vstem of the tobacco stem extract was measured, and the real-time flow rate of the premixed tobacco leaf extract was calculated using the formula T×Sstem×Vstem÷Sleaf. Wherein, Sleaf is the solid content of the tobacco leaf extract obtained in step (3), and Sstem is the solid content of the tobacco leaf extract obtained in step (2).

[0016] In some implementations, steps (2) to (4) are not in any particular order.

[0017] In some implementations, step (5) is performed simultaneously with steps (2) and (3), or after steps (2) and (3).

[0018] In some implementations, after obtaining the real-time flow rate of tobacco leaf extract or tobacco stem extract in step (5), the flow rate is automatically adjusted by the production control system to achieve real-time adjustment of the flow rate of the premixed tobacco leaf extract or tobacco stem extract.

[0019] In some implementations, the sensory quality of tobacco smoking is improved by achieving real-time adjustment of the flow rate of premixed tobacco leaf extract or tobacco stem extract to obtain a coating liquid with stable quality.

[0020] In some implementations, near-infrared spectroscopy is used to detect the total sugar content of premixed tobacco stem extract and tobacco leaf extract in real time.

[0021] In some embodiments, T is 30% to 35%, 35% to 40%, 40% to 45%, 45% to 50%, 50% to 55%, and 55% to 60%.

[0022] In some embodiments, the preparation method of tobacco stem extract or tobacco leaf extract is as follows: tobacco stem or tobacco leaf raw materials are mixed with 6-7 times the amount of water at a water temperature of 60 to 70°C, and extracted by a hydraulic pulper.

[0023] On the other hand, this application provides a method for preparing a reconstituted tobacco coating liquid, the method comprising: obtaining a mixture of tobacco leaf extract and tobacco stem extract by means of the method described above, concentrating the mixture, and then mixing it with tobacco flavoring to form a reconstituted tobacco coating liquid.

[0024] In some embodiments, the mixture is concentrated to 1.200 g / cm³. 3 density.

[0025] In some embodiments, the tobacco aroma is selected from floral flavorings, fruit flavorings, alcoholic flavorings, or any combination thereof.

[0026] In some embodiments, the coating liquid further includes one or more of the following: a fumigating agent, an adhesive, a dispersant, a food additive, or any combination thereof.

[0027] On the other hand, this application provides a method for preparing cigarette raw materials, the method comprising: obtaining a coating liquid by means of the method described above, coating a film substrate, drying it, and obtaining cigarette raw materials;

[0028] Optionally, the cigarette raw material is shredded and filled into a cigarette tube to obtain a cigarette.

[0029] In some embodiments, the drying process involves drying the coated substrate to a moisture content of 12%.

[0030] Terminology Definition

[0031] In this invention, unless otherwise specified, "reconstituted tobacco" refers to a product made from waste tobacco stems, tobacco dust, and tobacco fragments discarded during cigarette manufacturing, which is then processed into sheet or shred form and used as a cigarette filler. "Reconstituted tobacco" not only reduces cigarette costs but also helps to reduce tar and harmful substances and improve the intrinsic quality of cigarettes.

[0032] In this article, the term "brand" refers to different brands of cigarettes.

[0033] In this article, the term "cigarette stick" refers to different individual cigarettes under the same brand. Typically, cigarette sticks from different brands may have different dimensions, such as 20-24.5mm circumference, 19-20mm circumference, and 16-17mm circumference.

[0034] Beneficial effects

[0035] To save time and steps in preparing the coating solution, the inventors first mixed the tobacco stem extract and the tobacco leaf extract and then concentrated them, thus avoiding the time and steps wasted by concentrating the tobacco stem extract and the tobacco leaf extract separately.

[0036] Furthermore, through numerous experiments, the inventors obtained an index (i.e., total sugar) that can accurately characterize the solid content of tobacco stem extract and tobacco leaf extract in real time. This index is particularly suitable for characterizing the solid content of tobacco stem extract and tobacco leaf extract, and is significantly superior to other indexes.

[0037] Finally, the applicant adjusted the flow rates of the tobacco stem extract and tobacco leaf extract in real time by detecting the solid content in real time, so as to obtain a coating liquid with stable quality, thereby improving the sensory quality of tobacco smoking. Attached Figure Description

[0038] Figure 1 shows the correlation between total sugar content and solid content in tobacco stem extract.

[0039] Figure 2 shows the correlation between total sugar content and solid content in tobacco leaf extract.

[0040] Figure 3 shows the correlation between the relative density and solid content of tobacco stem extract.

[0041] Figure 4 shows the correlation between the relative density and solid content of tobacco leaf extract.

[0042] Figure 5 shows the correlation between the total alkali content and solid content of tobacco stem extract.

[0043] Figure 6 shows the correlation between total alkali content and solid content in tobacco leaf extract. Detailed Implementation

[0044] The technical solution of the present invention will be further described in detail below through embodiments. The illustrative embodiments and descriptions of the present invention are for explaining the present invention and do not constitute a limitation thereof. All raw materials used in the present invention are commercially available and commonly used; all equipment is commercially available and commonly used.

[0045] Example 1. The method of this application

[0046] Due to the inherent characteristics of the solids content detection method (solids content detection method: take 10g of extract in a weighing box, dry in a 100℃ drying oven for 3 hours, remove and place in a desiccator, and weigh after cooling to room temperature; the proportion of the remaining weight to the weighed weight is the solids content), it cannot be detected in real time. Therefore, in order to adjust the mixing flow rate of tobacco stem extract and tobacco leaf extract in real time, the inventors selected an indicator in advance that can accurately characterize the solids content of tobacco stem extract and tobacco leaf extract in real time through the following experiment.

[0047] 1. Selection of Indicators

[0048] First, tobacco stems and leaves were extracted using water extraction. Specifically, 6-7 times the volume of water was added to each of the stems and leaves, and the mixture was stirred at high speed using a hydraulic pulper at a controlled temperature of 60-70℃, resulting in stem extract and leaf extract, respectively. Then, the solid content of different batches of stem and leaf extracts was determined using a conventional solids content detection method (10g of extract was placed in a weighing box, dried in a 100℃ drying oven for 3 hours, removed and placed in a desiccator, and weighed after cooling to room temperature; the remaining weight as a percentage of the weighed weight is the solids content). Simultaneously, the total sugar content, total alkali content, and density of the stem and leaf extracts were determined, and linear equations were established between these values ​​and the solids content. Near-infrared spectroscopy was used to detect the total sugar and total alkali content of the stem and leaf extracts, and a hydrometer was used to detect the density of the extracts.

[0049] The results of total sugar and solids content tests of the stem and leaf extracts are shown in Tables 1 and 2 below. The results of density and solids content tests of the stem and leaf extracts are shown in Tables 3 and 4 below. The results of total alkali and solids content tests of the stem and leaf extracts are shown in Tables 5 and 6 below.

[0050] Table 1. Total sugar and solids content of stem extract

[0051]

[0052] Table 2. Total sugar and solids content of leaf extracts

[0053]

[0054] Table 3. Density and solid content of stem extract

[0055]

[0056]

[0057] Table 4. Density and solid content of leaf extract

[0058]

[0059] Table 5. Total alkali and solid content of stem extract

[0060]

[0061] Table 6. Total alkali and solid content of leaf extracts

[0062]

[0063]

[0064] Regression analysis was performed on the total sugar and solid content of the stem and leaf extracts, and the correlation coefficients R2 were all above 0.998 (Figure 1 and Figure 2). The experimental results show that the total sugar content is a good indicator of the solid content of the tobacco stem and leaf extracts.

[0065] Regression analysis of the relative density and solid content of stem and leaf extracts showed a correlation coefficient (R²) of only around 0.985 (Figures 3 and 4), which is significantly lower than the correlation coefficient of 0.998 for total sugar and solid content. This indicates poor data fitting and is not conducive to accurate online evaluation of solid content.

[0066] Regression analysis was performed on the total alkaloids and solid content of the stem and leaf extracts. The correlation coefficient R2 of the stem extract was only 0.952, and that of the leaf extract was only 0.98 (Figures 5 and 6). Both of these values ​​were significantly lower than the correlation coefficient of 0.998 for the total sugar and solid content, indicating poor data fitting and making it difficult to accurately evaluate the solid content online.

[0067] In summary, the experimental results show that different indicators have different effects on characterizing the solid content of tobacco stem extract and tobacco leaf extract, and total sugar content is the most suitable for characterizing the solid content of tobacco stem extract and tobacco leaf extract.

[0068] 2. The method of this application

[0069] Through the above screening, the most suitable index for characterizing the solid content of tobacco stem extract and tobacco leaf extract—total sugar—was obtained. The total sugar content was characterized by detection of total sugar, and the automatic adjustment of the mixing flow rate of tobacco stem extract and tobacco leaf extract was further achieved through the following method of this application:

[0070] (1) Extract the tobacco stems and leaves by water extraction, with the amount of water added being 6-7 times that of the raw materials and the water temperature controlled at 60-70℃, to form stem extract and leaf extract respectively;

[0071] (2) Automatic preparation of stem and leaf extracts:

[0072] The total sugar content was detected online using near-infrared spectroscopy, and then converted into the solid content of the stem and leaf extracts according to a linear equation, thus enabling online detection of the solid content of the stem and leaf extracts.

[0073] Specifically, the ratio of stem to leaf solids content in the coating solution should be designed as follows:

[0074] T = Sstem × Vstem : Sleaf × Vleaf

[0075] Wherein, S_stem is the solid content of the stem extract, V_stem is the flow rate of the stem extract, S_leaf is the solid content of the leaf extract, and V_leaf is the flow rate of the leaf extract. Depending on the brand, the stem-leaf solid content formula design ratio T is 30%-60% (the specific value of T is determined according to the specific brand of tobacco used, and the T value ranges from 30% to 60%).

[0076] Using leaf extract as the primary scale, flow rate matching was performed based on real-time monitoring results of the solid content of stem and leaf extracts, as follows:

[0077] Vstem = T × Sleaf × Vleaf ÷ Sstem. The flow rate is automatically adjusted through the production control system to achieve automatic matching of the extract.

[0078] (3) After automatic matching, the stem and leaf extract is concentrated using a falling film concentrator to the required density of 1.200 g / cm³. 3 .

[0079] (4) The concentrate is matched with tobacco flavoring to form a coating liquid for papermaking reconstituted tobacco production.

[0080] Example 2. Comparison of the method of this application with existing technical methods

[0081] 1. Comparison of solid content

[0082] Compared to the method of this application, the prior art prepares the coating solution by separately concentrating the stem and leaf extracts before blending. This embodiment compares these two methods. Specifically, the prior art method prepares the stem and leaf extracts according to the steps of Example 1, and then separately concentrates the stem and leaf extracts to 1.200 g / cm³. 3 The density is then adjusted according to the formula design requirements.

[0083] The solid content results determined by the two methods are shown in Table 7.

[0084] Table 7. Solid content control of the concentrated stem and leaf extract

[0085]

[0086]

[0087] As can be seen from the control of solid content, the coefficient of variation of solid content in the concentrate prepared by the method of the present invention is only 28.6% of that in the comparative example. The coefficient of variation indicates the fluctuation and uniformity of solid content. Therefore, the coating solution prepared by the method of the present invention has less fluctuation and better uniformity.

[0088] In summary, the method of the present invention, through real-time online monitoring of the extract for precise proportioning, achieves a significantly higher level of stability control for the leaf and stem concentrates than the comparative example.

[0089] 2. Comparison of sensory quality

[0090] Sensory quality sample preparation and evaluation method: The slurry from the production process was used to prepare a sheet base. The same weight of concentrated liquid obtained by the method described in this application and existing techniques was weighed and evenly coated onto the sheet base. The sheet base was then dried in a drying oven until the moisture content reached 12%. After being shredded, the shredded material was filled into an empty tobacco pipe to produce a cigarette. Eight evaluators were used to score the cigarettes, and a comprehensive score was calculated. The sensory evaluation results are shown in Table 8 below.

[0091] Table 8. Sensory evaluation results

[0092]

[0093] Experimental results show that the concentrated coating solution prepared by the method of this application improves the sensory quality of tobacco after coating the tobacco sheet.

[0094] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit them; although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications can still be made to the specific implementation of the present invention or equivalent substitutions can be made to some technical features without departing from the spirit of the technical solutions of the present invention, and all such modifications and substitutions should be covered within the scope of the technical solutions claimed in the present invention.

Claims

1. A method for real-time adjustment of the flow rate of premixed tobacco leaf extract or tobacco stem extract, the method comprising: (1) Prepare premixed tobacco stem extract and tobacco leaf extract separately; (2) The total sugar content of the premixed tobacco stem extract is detected in real time, and the solid content of the tobacco stem extract is calculated by the linear equation y = 0.6376x + 0.081; where x is the solid content of the tobacco stem extract and y is the total sugar content of the tobacco stem extract; (3) The total sugar content of the premixed tobacco leaf extract is detected in real time, and the solid content of the tobacco leaf extract is calculated by the linear equation y = 0.8169x + 0.1317; where x is the solid content of the tobacco leaf extract and y is the total sugar content of the tobacco leaf extract; (4) According to the selected tobacco stem and tobacco leaf brands, the stem-to-leaf solid content ratio T is set in advance, where T is selected from 30% to 60%; (5) The real-time flow rate V_leaf of the tobacco leaf extract is measured, and the real-time flow rate of the premixed tobacco stem extract is calculated by the formula T × S_leaf × V_leaf ÷ S_stem; where S_stem is the solid content of the tobacco stem extract obtained in step (2), and S_leaf is the solid content of the tobacco leaf extract obtained in step (3). The solid content of the leaf extract; or, the real-time flow rate Vstem of the tobacco stem extract is measured, and the real-time flow rate of the premixed tobacco leaf extract is calculated by the formula T×Sstem×Vstem÷Sleaf; where Sleaf is the solid content of the tobacco leaf extract obtained in step (3), and Sstem is the solid content of the tobacco leaf extract obtained in step (2); where, after obtaining the real-time flow rate of the tobacco leaf extract or the real-time flow rate of the tobacco stem extract in step (5), the flow rate is automatically adjusted by the production control system to achieve real-time adjustment of the flow rate of the premixed tobacco leaf extract or the tobacco stem extract.

2. The method of claim 1, wherein, The total sugar content of premixed tobacco stem extract and tobacco leaf extract can be detected in real time using near-infrared spectroscopy.

3. The method of claim 1, wherein, T is 30% to 35%, 35% to 40%, 40% to 45%, 45% to 50%, 50% to 55%, and 55% to 60%.

4. The method of claim 1, wherein, The preparation method of tobacco stem extract or tobacco leaf extract is as follows: mix tobacco stem or tobacco leaf raw materials with 6-7 times the amount of water, the water temperature is 60 to 70℃, and extract through a hydraulic pulper.

5. The method of claim 1, wherein steps (2) to (4) are not in any particular order.

6. The method of claim 1, wherein step (5) is performed simultaneously with steps (2) and (3), or after steps (2) and (3).

7. A method for preparing a reconstituted tobacco coating solution, the method comprising: A mixture of tobacco leaf extract and tobacco stem extract is obtained by the method according to any one of claims 1-6, the mixture is concentrated, and then mixed with tobacco flavoring to form a reconstituted tobacco coating solution.

8. The method of claim 7, wherein, The mixture was concentrated to 1.200 g / cm³. 3 density.

9. The method of claim 7 or 8, wherein, The tobacco aroma is selected from floral flavorings, fruit flavorings, alcoholic flavorings, or any combination thereof.

10. The method of claim 7, wherein, The coating liquid further includes: a fumigating agent, an adhesive, a dispersant, a food additive, or any combination thereof.

11. A method for preparing cigarette raw materials, the method comprising: After obtaining the coating liquid by the method according to any one of claims 7-10, the film base is coated, dried, and cigarette raw material is obtained.

12. The method of claim 11, wherein, The drying process involves drying the coated substrate to a moisture content of 12%.

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