A method for processing green tobacco leaves into tobacco shreds

Abstract

This invention belongs to the field of tobacco production and processing, and discloses a method for processing green tobacco leaves into shredded tobacco. More specifically, this invention provides a method for producing shredded tobacco for cigarettes and other tobacco products through an innovative combination of existing technologies, conventional leaf threshing and re-drying processes, and shredding techniques. The shredded tobacco is made entirely from green tobacco leaves grown on farms, thereby reducing investment and operating costs. Currently, the produced shredded tobacco has the advantages of increasing filler content, improving the operational performance of cigarette factory equipment, enhancing the technical quality indicators of individual cigarettes, and maintaining at least the same original tobacco flavor as current conventional industrial technologies.

Description

Technical Field

[0001] Generally, this invention belongs to the field of tobacco production and processing. More specifically, this invention relates to a method for processing green tobacco leaves into tobacco shreds for cigarettes and other products through an innovative combination of pounding and re-drying (GLT) and key processes. This method has low investment and operating costs, produces tobacco shreds with high filling value, and its flavor is approximately equivalent to that of the original tobacco. Background Technology

[0002] The global tobacco industry has undergone significant changes over the past 30 years. Brazil, the world's second-largest tobacco producer and largest exporter of green tobacco, best represents global trends excluding China. From 1990 to 2004, Brazil's total green tobacco production increased from approximately 300 million kilograms to nearly 700 million kilograms, with Virginia flue-cured tobacco accounting for 85% of the total; over 15 years, overall tobacco production increased by 133%. Part of the reason for Brazil's tobacco production growth was the significant decrease in tobacco production in the United States, Zimbabwe, and Europe during this period. In the most recent 15 years, from 2005 to 2020, Brazil's green tobacco production declined from 700 million kilograms to 500 million kilograms; now, nearly 90% of Virginia tobacco is flue-cured. In Brazil, the overall tobacco production decline over 15 years was close to 30%, while tobacco production in other countries around the world declined by about 20%.

[0003] With global conventional cigarette consumption projected to continue its decades-long trend of declining by 2-3% annually, the entire global tobacco production supply chain—from tobacco farmers to GLT (Gross Tobacco Processors) to cigarette manufacturers (including primary and secondary manufacturers)—is likely to continue to align with current industry trends, leading to a comprehensive reduction in conventional cigarette production and overall tobacco consumption. Successful companies to survive in this environment will either have to differentiate their products from the competition (a difficult feat in a market like tobacco) or, more likely, strive to become low-cost producers in their respective tobacco markets.

[0004] In light of this global context, the invention described herein helps the tobacco industry reduce capital used in tobacco production and industrial processes, lower overall operating costs of cigarette production, maintain cigarette production quality standards at internationally acceptable levels, and contribute to the Sustainable Development Goals (SDG 9 "Industrial Innovation and Infrastructure" and SDG 12 "Responsible Consumption and Production") set by the United Nations.

[0005] Therefore, it is necessary to define some common leaf-processing terms in tobacco processing and cigarette manufacturing:

[0006] - GLT (Grossed and Re-dried): This refers to the process of threshing, re-drying, pressing, and packaging green tobacco leaves delivered by tobacco farmers in a factory.

[0007] - Main process: Completed in some cigarette factories, the tobacco is mixed, rehydrated, shredded, dried and flavored before rolling, also known as the pre-processing area.

[0008] - Secondary processing: Completed at the cigarette manufacturing plant.

[0009] Green tobacco leaves: tobacco that is only cured in the tobacco farmer's curing barn by circulating hot air, "without fermentation" and without industrial re-drying.

[0010] Raw tobacco shreds: refers to tobacco that has been cut into thin strips for use in cigarette manufacturing. Also known as tobacco shreds.

[0011] In the pre-industrial stage, tobacco farmers:

[0012] Sowing tobacco seeds;

[0013] Tobacco cultivation;

[0014] Harvesting tobacco leaves;

[0015] Tobacco leaves are dried / cured (without fermentation) in a curing barn;

[0016] Tobacco leaf classification;

[0017] The tobacco leaves are packaged in bales, or packaged using similar farmer packaging methods, and then delivered for threshing and re-drying.

[0018] After being packaged at the tobacco farmers' facilities, the bundled or loose tobacco leaves are sent for routine threshing and re-curing. Currently, almost all tobacco leaves worldwide undergo threshing and re-curing in accordance with [the relevant regulations / standards]. Figure 1 Similar, or slightly different.

[0019] The known processing techniques are described in several patent documents: Patent EP 2489283 – “Method for processing tobacco leaves”, which reveals the standard of five threshing stages used in industry.

[0020] Patent WO 2019020370 – “Method for producing tobacco shreds” discloses a method comprising the following steps: harvesting tobacco leaves; fermenting the harvested tobacco leaves; threshing the fermented tobacco leaves into threshed tobacco material; moistening the threshed tobacco material; shredding the moistened tobacco material into tobacco shreds and drying it.

[0021] However, apart from the requirement to ferment tobacco in patent WO 2019020370, these processes still use conventional methods and have not promoted a market-accepted method for tobacco production that can reduce overall costs and manufacturing steps.

[0022] Patent WO 2019020370 – “Method for producing tobacco shreds” requires the width of the tobacco shreds to be between 1.3 mm and 1.7 mm, which is greater than the conventional shred width.

[0023] However, the current patent applies to any commercially required shredding width, including those in the range of 0.30 mm or less, and those up to and over 1.7 mm or greater.

[0024] In addition, a leaf-threshing plant (leaf-threshing and re-drying) is a factory that receives green tobacco leaves from tobacco farmers and performs the following steps:

[0025] Bundling treatment: Tobacco farmers can choose to have their bundles treated and softened in a vacuum chamber.

[0026] Tobacco grading: Grades and blends are determined by the farm’s products according to the customer’s specifications.

[0027] Leaf tip processing: Leaf tip processing includes leaf tip cutting. These steps bypass the leaf threshing production line, thereby improving the crushing efficiency of the leaf re-drying process and the screening efficiency in the main processes.

[0028] Tobacco leaf rehumidification: The tobacco leaves are loosened and softened by steam in a loosening rehumidification chamber. Rehumidification allows for minimal leaf breakage during threshing. It also controls product temperature to ensure the tobacco's aroma is not lost.

[0029] Leaf threshing and re-drying: Using a leaf threshing frame, the tobacco leaves are "peeled" from the tobacco stems by rotating teeth that fix the frame, and the tobacco leaves that enter become tobacco leaves and tobacco stem products.

[0030] Tobacco leaf separation: A classifier is used to separate the product from the threshing machine into sheet tobacco and stem tobacco; a combination of multiple threshing heads and grading machines is used to ensure optimal threshing results and minimal waste.

[0031] Drying: After separation, the tobacco leaves and stems will be dried again in a separate belt dryer.

[0032] Compression: The re-dried tobacco leaves and stems are individually packaged into cardboard boxes for final delivery to the user's main plant.

[0033] Figure 2 It describes the conventional main tobacco processing, in which the tobacco flakes and stems obtained by threshing and re-drying are received and ultimately used in individual blends to meet each consumer's requirements for cigarette blends.

[0034] Conventional tobacco processing mainly involves receiving tobacco flakes and stems obtained through threshing and re-drying, which are then used in the following processes:

[0035] A) Tobacco processing

[0036] The tobacco flakes move forward on the blending production line, passing through a slicer and then into a DCCC (Direct Rehydration and Feeding Machine), where the tobacco flakes are rehydrated and fed according to the different blends. The moistened tobacco then enters a flake hopper for storage and expansion. Optionally, it can also undergo additional rehydration via a steam passage. The flakes then enter a shredder to form shredded tobacco. Optionally, the flakes can also be further rehydrated and / or expanded via a steam passage before entering the dryer. After shredding, the flakes enter the dryer to obtain the required moisture content, desired expansion, and tobacco flavor characteristics for each blend. Optionally, the flakes can enter a cooler for cooling and / or removal of undesirable stem portions (typically a maximum dry flake input of 1%). At the main flake production line blending station, the dry tobacco is blended with dry tobacco from the stem hopper, stems (see B – Stem Processing), and other tobacco products such as flakes, expanded tobacco, and recycled tobacco. The product is first passed through a vibrator (optionally) and then through a finished tobacco flavoring machine. After flavoring, the mixture is conveyed to the finished product silo (optional) for homogenization, ensuring the necessary moisture for the blend or final step. The finished tobacco mixture is then sent to a secondary processing plant for cigarette manufacturing, or the product is pressed / packaged in cardboard boxes (including optional perforated liner bags). The product can be used anywhere as needed, but is best used within 6 to 12 months of the final packaging date.

[0037] B) Tobacco Stem Processing

[0038] The cardboard boxes of tobacco stems are placed into a dump truck. They are then sent to a washer for washing and to equipment for rehydration. The damp tobacco stems are then sent to a tobacco stem silo for storage and expansion, optionally with steam rehydration, and then to a shredder. After being cut into shreds, the stems enter a dryer to obtain the required moisture and expansion, and are then stored in a stem shredder or other packaging for further blending with sheet tobacco. Summary of the Invention

[0039] Figure 3 A new tobacco processing method is introduced, and Figure 1 The conventional leaf re-drying and Figure 2 Compared to the main process shown, this method combines conventional leaf threshing and re-drying with conventional main processes into a process with lower investment and operating costs, producing tobacco with higher filling value and improving screening efficiency, while highly preserving the original tobacco flavor from tobacco farmers.

[0040] The tobacco processing method specifically includes the following steps:

[0041] a) Tobacco leaf grading and blending;

[0042] b) Leaf tip processing, to obtain leaf stalk and leaf tip, wherein the cut leaf tip accounts for 30% to 35% of the total leaf weight;

[0043] c) The leaf stalks and tips become damp again;

[0044] d) Selection of leaf stalks and tips;

[0045] e) Leaf stems are removed to form tobacco flakes and tobacco stalks;

[0046] f) Separation of tobacco leaves and stems;

[0047] Steps e) and f) are performed in three leaf-beating / separation stages;

[0048] g) Mix the leaf tips with tobacco leaves, rehydrate the tobacco leaves, and add tobacco leaves as a feeder; the "tobacco leaves" mentioned in the process after mixing the leaf tips with tobacco leaves is actually a mixture of leaf tips and tobacco leaves;

[0049] h) The tobacco flakes are stored in the mixing silo for puffing;

[0050] i) Tobacco sheets are cut into shreds;

[0051] j) Drying of tobacco shreds;

[0052] k) Remove bad stems from the tobacco.

[0053] In step a), the tobacco leaves are roasted but not fermented, and bundled with a moisture content of 18% to 19%.

[0054] In step b), the leaf tip is processed by two to five adjustable circular blades spaced 25 mm to 50 mm apart, wherein the number of blades and the cutting size vary depending on the type of tobacco.

[0055] Before the selection in step d), the leaf stalks and tips are steam-rehydrated in a rotating rehydration chamber to achieve a moisture content of 18% to 19%.

[0056] The tobacco stems separated in step f) are steam-rehydrated, cut into shreds, dried in a drum dryer, and mixed with tobacco shreds.

[0057] The leaf-cutting / separation stage is selected from vertical leaf-cutting / separator, horizontal leaf-cutting machine, countercurrent separator, multi-stage separator and their combination.

[0058] In step g), the moisture content of the tobacco is increased to 23% to 26% before the tobacco is shredded.

[0059] In step j), the moisture content of the tobacco shreds is reduced to 11% to 14% by using a drum dryer.

[0060] After step h) and before step j), the tobacco is steam-rehydrated through a steam channel.

[0061] Step k) is performed using a vertical air separator.

[0062] After step k), the tobacco is cooled by a cooler.

[0063] After step k), the tobacco is passed through a vibrating screen to remove fine particles and dust.

[0064] The tobacco processing method further includes the following steps:

[0065] l) Pass the tobacco through the flavoring machine;

[0066] m) The tobacco shreds are pressed and packaged.

[0067] Prior to step m), the tobacco shreds are stored in a hopper for homogenization.

[0068] The following features differ from conventional processes and can be operated individually or in combination:

[0069] In the initial blending stage, the tip processing of both "filler" and "tobacco leaves" is directly increased to 30%-35% of the total weight of the tobacco. This process is most effective in countries where tobacco farmers supply tobacco in bundles or loose leaves. The tobacco leaves can be Virginia-type tobacco, air-cured burley tobacco, or any other form of tobacco; regardless of whether it is fermented or otherwise processed.

[0070] Compared to a conventional 5-stage leaf-cutting production line, the subsequent leaf-cutting and separation capacity is reduced by at least 10% to 20%.

[0071] The belt dryer used for drying green tobacco strips after leaf trimming has been phased out.

[0072] The dry sheet tobacco tablet press after the dryer has been phased out.

[0073] Achieving a significant, ultimately acceptable, stem removal rate is crucial in the primary process, rather than in the leaf threshing and re-drying. This necessitates equipping the tobacco dryer with a highly efficient stem separator.

[0074] Compared with conventional leaf re-drying and main tobacco shred production, it significantly increases the filling value of the produced tobacco shreds and reduces the tobacco shred weight requirement for each cigarette produced.

[0075] Maintain a high percentage of original tobacco flavor and a high filler value.

[0076] Compared with conventional processes, it reduces the total investment and operating costs of leaf pounding and re-drying and the main processes, and increases the filling value of the finished tobacco shreds.

[0077] Compared with conventionally produced tobacco, it improves the operating performance of medium- and high-speed cigarette making machines and reduces the rate of cigarette scrap.

[0078] Tobacco produced using this method retains the smoking characteristics of conventionally processed tobacco compared to conventionally processed blends. Attached Figure Description

[0079] To enable any person skilled in the art to fully understand and practice this invention, it will be described in a clear, concise, and sufficient manner with reference to the accompanying drawings, which illustrate and provide supplementary information about the invention:

[0080] Figure 1 This is a flowchart of a conventional tobacco processing plant (leaf threshing and re-drying).

[0081] Figure 2 This is the standard main tobacco processing procedure;

[0082] Figure 3 This is a flowchart of a tobacco processing method, some of which are combined with conventional leaf threshing and re-drying and other conventional main processes. Detailed Implementation

[0083] generally, Figure 3 The method shown applies to green tobacco leaves from all countries, especially those from countries where the leaves are bundled or loose from farmers to threshing and re-drying plants. Countries that supply farmers with green tobacco leaves to threshing and re-drying plants without bundling or loosening the leaves will require a similar approach. Figure 1 While possessing good leaf re-drying ability and lower sieving and filling values, it can still benefit from the remaining features and embodiments of the present invention.

[0084] The tobacco leaves from tobacco farmers are cured but not fermented, and typically have a moisture content of about 18%-19%.

[0085] "Fermented" tobacco is a special, labor-intensive process in which tobacco leaves are piled up and subjected to increased temperature and humidity levels to achieve unique characteristics distinct from green farmer-dried tobacco produced globally. It should be noted that this invention does not typically use "fermented" tobacco, but its use is not limited.

[0086] Compared with conventional leaf-beating and re-drying ( Figure 1 In contrast, this invention avoids three fundamental steps, which represents significant benefits in terms of quality and cost reduction:

[0087] 1) Less total green tobacco leaves undergo mechanical threshing. This is achieved by increasing the percentage of leaf tip processing at the initial blending production line, and removing the added unwanted stems from the leaf tips via a suitable air separator after the sheet tobacco dryer; 2) The tobacco leaves are not re-dried after threshing; 3) The tobacco leaves are not first pressed / packaged after threshing / drying.

[0088] Process steps

[0089] This invention utilizes flue-cured tobacco leaves directly from tobacco farmers, and its steps are as follows:

[0090] Tobacco Leaf Grading: Grading is determined by the farm's green tobacco leaves according to customer specifications. Production operations for each grade are planned to ensure product quality meets customer specifications.

[0091] Leaf tip processing: Leaf tip processing involves cutting the leaf tips, consisting of 2 to 5 or more adjustable cutters spaced approximately 1 to 2 inches (25 to 50 millimeters) apart, depending on the tobacco (“shredder” or “tobacco leaf”) and the desired amount of tobacco leaf fragments. The aim here is to increase the percentage of leaf tip processed “filler” and “tobacco leaf” to approximately 30%-35% of the total weight at the initial mixing table; this is a key factor in the overall positive outcome of this invention.

[0092] Tobacco leaf rehydration: Both topped and untopped tobacco leaves are loosened and softened using steam in a separate, loose rehydration chamber. Rehydration allows for minimal breakage during threshing. Product temperature is controlled to ensure that the aroma and flavor of the tobacco leaves are not lost. Only the remaining leaves (stems) are subsequently threshed.

[0093] Selecting leaf stems and tips;

[0094] Threshing and re-drying: Using a threshing basket and rotating teeth along a fixed track, the tobacco leaves at the stem are threshed and removed from the stem. The tobacco leaves entering the threshing basket are thus transformed into a product of tobacco leaves and stems;

[0095] Separation of tobacco leaves and stems: A classifier separates the product from the threshing machine into tobacco leaves and stems. Multiple threshing machines and separators can be used sequentially. Compared with conventional processes ( Figure 1 Compared to the previous method, when comparing the same input weight of tobacco leaves from farmers on a mixing table, the total amount of leaf threshing and separation will be significantly reduced, by at least 10%-20%. The tobacco strips are then mixed with the leaf tips to obtain composite tobacco strips, which proceed to the next industrial process. The tobacco stems can be dried or chopped for later use.

[0096] According to the present invention, the combined tobacco strip needs to undergo the following steps:

[0097] - Additional moisture and ingredients;

[0098] -Expanded material silo;

[0099] - Steam passage (optional);

[0100] - Shredder: Tobacco leaves are fed into the shredder with a preferred moisture content of 23%-24% to produce "shredded tobacco". However, the moisture content can be higher or lower depending on the tobacco blend and / or the capacity of the shredder; the shredder does not require special blades such as serrations (toothed), and the shredding width (cutting volume per inch (CPI)) is not limited to a specific range, but is generally used globally for extra-large, large, ultra-thin, extra-ultra-thin, nano, and hand-rolled (RYO). That is, the shredder's cutting volume per inch is 21 to 85, or the tobacco shred width is 1.2 mm to 0.3 mm.

[0101] - Steam expansion channel (optional);

[0102] The dryer reduces the moisture content of the feed material from 23%-24% to 11%-14% of the output. However, the moisture content of the feed and output may be higher or lower, depending on the specific mixture and the performance of the dryer. A drum dryer is best suited for this invention because it has lower investment costs and better smoke quality compared to an airflow dryer. While using an airflow dryer alone would increase the fill value, using this invention will produce a total finished tobacco fill value exceeding what an airflow dryer could achieve; coupled with the additional advantages of lower cost and improved tobacco smoke quality.

[0103] - An air separator for removing defective (OBJ) stems from tobacco leaves; for the purposes of this invention, the average amount of stems removed is 1%-3% of the original green tobacco leaf weight, but it can be higher or lower. The final tobacco leaf and stem content will meet customer requirements;

[0104] - Cooling roller (optional);

[0105] - Vibrating separator (optional);

[0106] -Fragrance dispenser;

[0107] - Homogenization silo (optional);

[0108] - Pressing / packaging.

[0109] After threshing, the bare tobacco stems can be dried in a dryer and then pressed / packaged in the same manner as regular threshing and re-drying. Figure 1 Alternatively, according to the present invention, the tobacco stem can be rehydrated directly during the final threshing of green tobacco leaves. Figure 3 Then, the shredded material is dried in a drum dryer.

[0110] tobacco performance

[0111] Several embodiments are described to support the invention, the first of which relates to tobacco leaf performance. This process produces better tobacco strips due to a specially designed tip-processing function, preferably comprising 2 to 5 adjustable cutters spaced approximately 1 to 2 inches (25 to 50 mm) apart, which, for the “filler” and / or “tobacco leaf,” constitute approximately 30%-35% of the total leaf weight. Bypassing the threshing section would produce more and larger tobacco tips and strip fragments. Therefore, only the leaf stem portion remaining after the tip is cut is threshed, resulting in better overall tobacco strip fragments.

[0112] Limiting leaf tip cutting helps determine the number and width of pruning stages required for a specific yield; however, leaf tip cutting can result in a reduction of up to approximately 20%. For example, compared to conventional pruning and re-drying (… Figure 1 Compared to this, the third and fourth stages can be omitted. This should be considered merely as an example, and other possible configurations using the present invention and its embodiments are not excluded.

[0113] A specially designed leaf tip processing function can produce undesirable stems in the tobacco shreds after the tobacco shredder, which is detrimental to cigarette quality and leads to defective products during production, especially on today's high-speed cigarette machines. To minimize this problem, an air separator is introduced after the tobacco dryer. Figure 3 This eliminates the problem of tobacco strands forming due to excess undesirable stems during cigarette manufacturing, ensuring high-quality cigarette products. Depending on the tobacco blend (shredder or tobacco leaves), the balance between the maximum percentage of stems allowed to enter the shredder and the stem removal capacity of the separator helps determine the tip percentage of total green leaf intake at the threshing and re-drying mixing station. Figure 3 ).

[0114] tobacco stem performance

[0115] Green tobacco stems processed and cut according to the present invention ( Figure 3 Compared to tobacco stems processed in conventional leaf threshing and main operations ( Figure 1 and 2 This improved the filling value and screening efficiency.

[0116] After threshing, the bare tobacco stems can be dried in a belt dryer and pressed / packaged for future use in conventional main processes. Figure 2 ); or; according to the present invention, the tobacco stem can be rehydrated directly during the final threshing of green tobacco leaves ( ); Figure 3 Then it is cut and dried in a drum dryer for future addition back into the main process of the invention or conventional processes.

[0117] This invention avoids the drying and pressing / packaging of the middle tobacco stems. The bare tobacco stems are first cut to be dried sequentially in a drum dryer. An additional advantage of this invention is that it provides stems with a higher filler value.

[0118] Tobacco product quality

[0119] When the tobacco produced by this invention accounts for 20%-40% of the total blend, the finished tobacco produced by this invention allows the weight of a typical single extra-large cigarette tobacco to be reduced from 725-735 mg to 675-700 mg; by increasing the tobacco sheets and stems produced by this invention to 41%-100% of the total blend, single cigarette tobacco weighing less than 675 mg can be obtained. Each tobacco blend and cigarette-making machine requires production trials to determine the final optimization.

[0120] Finally, the products obtained using this invention result in lighter tobacco weight per cigarette, more uniform tobacco stick hardness, lower rate of loose ends, improved operating performance, and lower cigarette scrap rate for modern medium- and high-speed cigarette rolling machines. Equally important, the tobacco produced using this invention retains the original color, aroma, and flavor of the tobacco leaves roasted by tobacco farmers, at a level at least equivalent to tobacco leaves produced by conventional leaf threshing, re-drying, and other main processes.

[0121] Use equipment

[0122] Through the process of this invention, the capacity of a conventional leaf-cutting production line can be reduced to at most two leaf-cutting production line stages, or approximately 20% of the capacity of conventional leaf-cutting and re-drying. Figure 1 This is a significant economic advantage; it reduces equipment, floor space, and energy consumption.

[0123] This method does not require a conventional 5-stage production line, but allows the use of existing leaf-baking and re-drying equipment, which can be rearranged by eliminating and / or replacing steps and equipment to achieve the process results of this invention.

[0124] If a company already has conventional threshing and re-drying equipment, and this equipment is located in the same position as the main equipment, it can be used to directly feed tobacco strips from any stage of the separator (ideally after the first and second stages) of the threshing and re-drying equipment into the tobacco strip feeder of the main equipment; or, when the tobacco strips need to be transported to another part of the main equipment or need to be mixed with other grades of tobacco strips from the main equipment, they need to be packaged. However, this approach must be balanced with the process and all its related embodiments.

[0125] This embodiment describes another feature of the invention. Any conversions or modifications made to the tobacco re-drying or tobacco processing line, or any features derived therefrom, to achieve the results of the invention are part of this patent.

[0126] Flexibility of using different devices

[0127] This invention does not require a specific type of threshing or drying equipment. The process of this invention can use a vertical threshing machine / separator (VT), a conventional horizontal threshing machine, a countercurrent separator (CF), a multi-stage separator (MS), or a combination thereof for threshing; and, depending on the end use, a drum dryer or airflow dryer for drying sheet tobacco, and / or a stem and ribbon dryer or drum dryer. Even manual stripping of tobacco can replace mechanical threshing, followed by the subsequent steps outlined in the patent.

[0128] The process of this invention allows existing and / or used equipment, as well as some new equipment, to be relocated and repositioned in order to achieve the results of the method of this invention.

[0129] therefore, Figure 3 The process can be explained, and Figure 1 and Figure 2 Referencing conventional leaf re-drying and main configurations, to highlight the differences from the present invention.

[0130] Environmental friendly

[0131] The production concept of this invention encompasses carbon emission allowances or carbon trading in the carbon market because it reduces greenhouse gas emissions, thus increasing the amount of carbon available for sale if emissions are below the limit, or reducing the amount of carbon purchased if emissions are above the limit. This applies only to countries where it is legally required or possible to do so.

[0132] This invention promotes a change in the economical production of tobacco for cigarettes by effectively reducing the electricity and fuel used for steam production by eliminating the dual drying process, the dual pressing process, and reducing leaf threshing / separation and transportation between stages.

[0133] This invention follows the Sustainable Development Goals (SDG9: “Industrial Innovation and Infrastructure” and SDG12: “Responsible Consumption and Production”), also known as the Global Goals, which were adopted by all UN Member States in 2015 as a universal call for action to protect the planet by 2030, with a particular focus on environmental sustainability.

[0134] Energy saving

[0135] By eliminating two industrial belt dryers for tobacco flakes and stems, we achieved economic benefits from steam, thereby saving boiler fuel, whether from hydrocarbons, firewood, coal, electricity, or other sources. To quantify the energy gain from eliminating tobacco flake and stem dryers in conventional tobacco re-drying, the following criteria can be used:

[0136] - Tobacco sheet dryer: For every kilogram of tobacco sheet, the drying section requires an average of 0.30 kg of steam, and the rehumidification section requires 0.15 kg of steam.

[0137] - Stem dryer: On average, 0.35 kg of steam is needed to dry each kilogram of stems.

[0138] Therefore, a tobacco production line with a capacity of 10,000 kg (including 8,000 kg of tobacco leaves and 2,000 kg of tobacco stems) is economically viable when the steam output of the tobacco leaf dryer is 3600 kg / h, the steam output of the tobacco stem dryer is 700 kg / h, and the total steam output is 4300 kg / h. This means that using logs (40% moisture content / 75% energy efficiency) at approximately 2.9 cubic meters / h or using BPF fuel oil (90% energy efficiency) at 290.6 kg / h is economically viable. Considering that the average steam output required for conventional 10-ton / h tobacco leaf re-drying is 6000 kg / h to 7000 kg / h, the steam output is reduced to 4300 kg / h by eliminating the tobacco leaf and stem belt dryers, which is equivalent to a 70% to 60% reduction in steam output by this invention.

[0139] Considering there are 22 days in a month and 8 hours per shift:

[0140] - Timber economics: 2.9 cubic meters × 8 hours × 22 days = 510.4 cubic meters / month.

[0141] -BPF fuel economy: 290.6 kg / hour × 8 hours × 22 days = 51145.6 kg / month.

[0142] Regarding carbon emission credits, the absorption of atmospheric carbon dioxide by tree growth is achieved by determining the potential carbon storage of tree species, and carbon emission credits are generated due to the sequestration of greenhouse gases. According to Silva et al. (1996) in a public publication of the Brazilian National Institute of Agricultural Research (Embrapa) (ISSN 1980-3958, August 2011), the formula for estimating carbon storage by reducing eucalyptus biomass used for steam generation is: C content = (log volume + 25%) x (basic density 0.49) x (carbon content 0.42).

[0143] Considering that the reduction in wood consumption due to this invention is 2.9 cubic meters per hour, the log usage is 510.4 cubic meters per month, the C content = (510.4 + 127.6) × 0.49 × 0.42 = 131.3 carbon reserves per month, with each shift lasting 8 hours per day (22 days per month).

[0144] This invention eliminates several conventional steps, which allow for a significant reduction in equipment and energy savings:

[0145] - A sheet smoke belt dryer;

[0146] - A stem ribbon dryer;

[0147] - A hydraulic press unit;

[0148] -All third leaf-cutting stages;

[0149] -All fourth leaf-cutting stages;

[0150] - A slicer that cuts pressed tobacco into slices;

[0151] - A rehumidifier for dried tobacco stems.

[0152] Total power reduction by reducing steps: approximately 600 kW, or 105,600 kW / month, considering an 8-hour shift / day (22 days / month). Considering that a conventional blade-cutting line with a processing capacity of 8 to 10 tons / hour consumes an average of 1,500 kW of electricity, this translates to an average energy reduction of 40%.

[0153] In conventional processes, the moisture content of tobacco leaves from farmers is approximately 18% / 19%, and in the final step of the process, it is dried to 12.5% ​​for packaging. Therefore, it is necessary to rehydrate the tobacco leaves, from 12.5% ​​to 23% / 24% for shredding, and then further reduce the moisture content to 11%-14% for final shredding and blending. However, in the method of this invention, the moisture gradient from raw tobacco leaves to shredded tobacco is simply from raw tobacco leaves (18% / 19%), to the threshed and trimmed tobacco leaves at the shredder (23%~26%), and finally to the final shredded tobacco (11%~14%). This means that the steam requirement is reduced by 10% to 20%.

[0154] The leaf-re-drying equipment is directly connected to the main equipment located in the same place. Figure 3 It significantly reduces logistics, eliminates intermediate transport by forklifts or trucks, improves efficiency, and reduces fuel consumption and pollution.

[0155] Compared to a conventional five-stage production line, this main equipment features tip processing and stem separation functions that are absent in threshing and re-drying equipment. It achieves the same throughput with only three production stages, while also saving significant energy. This invention uses a horizontal multi-stage separator in the first and second stages, and a vertical separator in the third and final stages. However, a horizontal multi-stage separator can also be used in the third stage. This invention does not require a specific type of threshing equipment and can utilize vertical threshing / separator (VT), horizontal threshing, "counter-current" (CF) separator, multi-stage separator (MS), or even manual stripping, or combinations thereof. The fundamental difference between the three stages and the conventional five stages is that the same throughput is maintained by increasing tip trimming in the main process through stem removal from the tip.

[0156] Process application flexibility of global cigarette manufacturers

[0157] The tobacco produced by this invention can not only be used as an additive in conventional main processes to other mixed components, but can also be dried and packaged according to the invention. Figure 3 Alternatively, it can be transferred as a finished mixture with added other components (recycled tobacco, stems, flakes, oriental tobacco) to secondary equipment for on-site packaging or for hand-rolling and other cigarette production.

[0158] Optionally, it can be directly fed into a secondary cigarette rolling machine ( Figure 3 ), and thoroughly remove tobacco beetles beforehand.

[0159] This embodiment also represents the flexibility of combining primary and secondary operations globally. Among other things, the invention also allows for the following options in cigarette manufacturing operations:

[0160] Existing conventional main equipment ( Figure 2 By installing sufficient blending stations, the capacity of existing main equipment can be increased by 10% to 100%, improving filler value, screening efficiency, and reducing costs by using tobacco shreds of the present invention produced worldwide. This alternative may require specific additional investments, such as adding silos, tablet presses, etc., to properly maintain the overall balance of the main equipment.

[0161] Initial selection auxiliary equipment can operate anywhere in the world without requiring tobacco stockpiles, blending lines, slicers, rehydration and blending silos, steam tunnels, tobacco leaf and stem shredders, stem and leaf dryers, coolers, etc. This can be achieved by setting up main equipment capable of producing various blends, requiring only blending lines, vibrators, flavoring machines, small dryers, and blending silos. The final cigarette blend can be transported directly from the silo to the cigarette factory or packaged for future use.

[0162] Process efficiency

[0163] The process of this invention eliminates the conventional leaf-beating and re-drying and conventional main processes ( Figure 1 and 2 Repeated pressing and packaging steps in )

[0164] Regarding leaf-cutting capacity, this invention is more compact and economical than conventional five-stage leaf-cutting production lines. Compared to conventional leaf-cutting and re-drying production lines, the total installed leaf-cutting capacity of this invention can be reduced by approximately 20%.

[0165] For flue-cured tobacco "filler" and / or flue-cured tobacco "leaves," the tip cutting of this invention accounts for 30%-35% of the total weight of the tobacco leaves, resulting in better tobacco leaf breakage. Compared to a 5-stage production line, this invention enables better tobacco leaf breakage even with only 2 or 3 leaf-beating stages.

[0166] Compared to conventional main processes, this process involves a higher percentage of stems processed by the tobacco shredder, which need to be removed by a suitable stem separator after the tobacco dryer.

[0167] This invention eliminates the need for the expensive sheet tobacco belt dryers used in conventional threshing and re-drying. It also eliminates the need for the high-capacity, high-stroke presses commonly found in conventional threshing and re-drying processes that post-process large quantities of sheet tobacco in belt dryers.

[0168] If the final mixing silo ( Figure 3 If the tobacco shreds are directly fed into the cigarette-making machine during secondary processing, the pressing / packaging step is also eliminated. This alternative method also requires adequate control of tobacco beetle pests.

[0169] It should be noted that these figures and descriptions are not intended to limit the implementation of the invention, but merely to illustrate and enable the understanding of the conceptual innovations disclosed herein. Therefore, the descriptions and images must be interpreted in an illustrative and non-limiting manner, and other equivalent or similar methods may be used to implement the invention; however, these methods do not depart from the scope of protection outlined in the proposed solutions.

Claims

1. A method of processing green leaf into cut tobacco, characterised in that, comprising the steps of: a) Tobacco grading and blending; the tobacco is cured but not fermented green leaf and baled at 18% to 19% moisture content; b) Tip processing to obtain lamina butt and leaf tip, wherein the cut leaf tip is 30% to 35% of the total leaf weight; c) Moisture conditioning of the lamina butt and leaf tip; d) Selection of the lamina butt and leaf tip; prior to selection, the lamina butt and leaf tip are separately steam conditioned in loose conditioning drums to achieve 18% to 19% moisture content; e) Leaf threshing to form cut lamina and tobacco stem; f) Separation of the cut lamina and tobacco stem; wherein steps e) and f) are carried out in three threshing / separation stages; g) Mixing of the leaf tip with the cut lamina, conditioning of the cut lamina and addition of cut lamina casing; the moisture content of the cut lamina is increased to 23% to 26%; h) Bulk storage of the cut lamina in a bulk bin for bulking; i) Cut tobacco drying to reduce the moisture content of the cut tobacco to 11% to 14% by a drum dryer; k) Removal of undesirable stem from the cut tobacco. In step b), the tip processing is carried out by two to five adjustable circular knives spaced 25 mm to 50 mm apart, wherein the number of knives and the size of the cut varies depending on the type of tobacco.

2. The method of claim 1, wherein, The threshing / separation stages are selected from one of a vertical threshing machine, a horizontal threshing machine in combination with one of a counter current separator, a multi-stage separator.

3. The method of claim 1, wherein, After step h) and prior to step i), the cut lamina is steam conditioned by a steam tunnel is included.

4. The method of claim 1, wherein, After step k), the cut tobacco is cooled by a cooler.

5. The method according to any one of claims 1 to 4, characterized in that, After step k), the cut tobacco is passed through a vibrating screen to remove fine particles and dust is included.

6. The method of claim 5, wherein, Further comprising the steps of:

7. The method of any one of claims 1, 3, 4, 6, wherein, 1) Passing the cut tobacco through a flavouring machine; m) Cut tobacco compression and packing is carried out. Prior to step m), the cut tobacco is stored in a bin for homogenization is included.

8. The method of claim 7, wherein, Step k) is carried out by a vertical air separator.

9. The method of any one of claims 1, 3, 4, 6, 8, wherein, The separated tobacco stem in step f) is steam conditioned, cut, dried in a drum dryer and mixed with the cut tobacco.

10. The method of any one of claims 1, 3, 4, 6, 8, wherein, ​

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