A cellar fermentation method for improving the organoleptic quality of cigar tobacco

Abstract

The application discloses a cellar fermentation method for improving sensory quality of cigar leaves, which is characterized by the following steps: fermenting the leaves in a cellar environment, so that slow chemical changes occur in the leaves, and meanwhile, the rich microorganisms in the soil contact with the leaves to accelerate the chemical change process; and fermenting the leaves in the cellar with constant temperature all the year round to balance the taste, improve the maturity, improve the smoking quality, improve the basic quality of raw materials, stimulate the characteristics of raw materials, and after fermentation, the cigar has mellow and sweet and slightly bitter aroma with long aftertaste.

Description

Technical Field

[0001] This invention relates to the field of tobacco processing technology, and in particular to a cellar fermentation method for improving the sensory quality of cigar tobacco leaves. Background Technology

[0002] Cigar tobacco has a rich, mellow aroma, a sweet and slightly bitter taste, and a long finish. However, due to differences in soil and climate, as well as different processing methods, the flavor of cigar tobacco often has a regional character, and there are also significant differences in strength, power, and aroma. These factors have led to the unsatisfactory use of domestically produced cigar tobacco in cigar processing, with mid- to high-end cigars heavily relying on imported raw materials. Summary of the Invention

[0003] The purpose of this invention is to provide a cellar fermentation method for improving the sensory quality of cigar tobacco leaves in order to solve the above-mentioned problems. This invention ferments tobacco leaves in a cellar with a constant temperature all year round in order to balance the taste, improve maturity, improve smoking quality, enhance the basic quality of raw materials, and bring out the characteristics of raw materials.

[0004] The present invention achieves the above objectives through the following technical solutions:

[0005] A cellar fermentation method for improving the sensory quality of cigar tobacco leaves includes the construction of a cellar site and a cellar fermentation process, wherein the cellar fermentation process includes two parts: fermentation using flavor media and fermentation using liquor cellar mud.

[0006] When the fermentation medium is a flavor medium, the following steps are included:

[0007] Leave a space of about 100 square meters in the middle of the cellar, bury the large wine jar entirely in the mud, leaving only the mouth of the jar exposed. Place a layer of flavoring medium about 2 cm thick at the bottom of the jar, then place sesame sheets on top, followed by about 25 kg of tobacco leaves. Cover the tobacco leaves with another layer of sesame sheets, then another layer of flavoring medium, then another layer of sesame sheets, and so on, repeating this process for four layers of tobacco leaves, totaling 100 kg. Cover the top layer of tobacco leaves with another layer of sesame sheets, then another layer of flavoring medium, and finally another layer of sesame sheets. Compact the mixture, cover the jar, and let it ferment in the cellar. Depending on the quality of the tobacco leaves, the fermentation time is between 10 and 30 days.

[0008] When the fermentation medium is baijiu cellar mud, the following steps are included:

[0009] Using 200 kg of tobacco leaves as a unit, each fermentation chamber holds two units of tobacco leaves. A breathable, soft cloth is laid flat under the tobacco leaves. The destemmed and peeled tobacco leaves are then stacked on the cloth, each stack 10 cm high. The first layer of tobacco leaves is arranged horizontally, and the second layer forms a 90-degree angle with the first. This stacking continues until 200 kg is filled. The cloth is then pulled up to completely wrap the tobacco leaves. Baijiu (Chinese liquor) cellar mud is poured over the wrapped tobacco pile, and the cloth is completely sealed. The bottom of the pile is compacted with cellar mud to prevent air leakage. Another layer of soft cloth is then placed on top of the cellar mud, ensuring it completely covers it. The cloth is moistened with distilled water to prevent the cellar mud from cracking. Fermentation time ranges from 15 to 40 days, depending on the quality of the tobacco leaves.

[0010] Fermentation media include the following:

[0011] (1) Flavor medium;

[0012] a) Baijiu lees: formed by deep fermentation and high-temperature cooking of lees. It has a low crude fiber content and is rich in crude protein, trace elements, amino acids, vitamins, yeast, etc., which can provide sufficient substrate nutrients for tobacco fermentation and accelerate the fermentation process. At the same time, the lees also contain a certain amount of alcohol, which can give tobacco leaves a liquor aroma.

[0013] b) Other flavoring agents: wintergreen gum, tea, sawdust, etc.; impart characteristic aromas to tobacco leaves and harmonize their flavor.

[0014] (2) Baijiu cellar mud;

[0015] Rich in high-quality yeast, acetic acid bacteria and other microorganisms and enzymes, it can accelerate chemical reactions during the tobacco leaf balancing process, degrade macromolecular compounds such as terpenes and proteins, balance the taste, coordinate the smoke, and catalyze the release of aroma substances from the tobacco leaves, highlighting the "sweet and mellow aroma" style characteristics.

[0016] The construction of the cellar site includes the following procedures:

[0017] 1. Cellar location: The top of the cellar must be at least 1 meter above the ground, the cellar height must be 3 meters, and the area must be at least 300 square meters;

[0018] 2. Cellar walls: Waterproofing treatment is applied to the four walls, top and bottom of the cellar, and thermal insulation coating is applied to all six sides of the walls.

[0019] 3. Cultivation Mud Pit: Construct a 1-meter-high, 3-meter-wide, and 5-meter-long cultivation pit using bricks against the wall of the cellar. The pit should be lined with bricks on all sides and at the bottom. This pit is used to store and cultivate the fermented mud. The fermented mud should be returned to the pit for recycling, and fresh yellow mud should be added to it periodically to cultivate new mud.

[0020] 4. Fermentation rooms: Five consecutive fermentation rooms are built side by side on each side of the cellar, separated by bricks, with a layer of bricks paved at the bottom. Each fermentation room is level with the top of the wall, 4 meters long and 4 meters wide.

[0021] 5. Cellar door: Made of pine or oak with suitable moisture content to avoid deformation of the door panel due to temperature differences between the inside and outside of the cellar. At the same time, to prevent sudden changes in the outside temperature from affecting the microclimate inside the cellar, a buffer zone should be designed in front of the cellar door, and a separate layer of insulation material should be added to this area.

[0022] 6. Cellar ventilation

[0023] (1) The flow of natural air can effectively remove the impurities produced during the fermentation of tobacco leaves, creating a better environment for the growth of tobacco leaves with a "mellow and sweet aroma".

[0024] (2) The fresh air inlet should be located away from odors, and a pre-filter should be used for the fresh air inlet.

[0025] (3) Requirements for the number of air changes in the cellar; the fresh air supply should reach 1-2 times per hour.

[0026] (4) Ventilation pipes should be installed in the cellar hall and fermentation room.

[0027] 7. Cellar interior lighting

[0028] (1) The interior lighting of the cellar should not be too bright; generally, it should be kept dim.

[0029] (2) Avoid excessively bright light, high heat, or ultraviolet radiation sources in the cellar. Fluorescent lamps produce a large amount of invisible ultraviolet radiation, which affects the quality of tobacco leaves and cannot be used as a lighting source for the cellar. Cold light sources or low-power incandescent lamps should be used in the cellar.

[0030] 8. Storage conditions

[0031] (1) Temperature: The cellar is at room temperature (10-18℃).

[0032] (2) Humidity: Keep the humidity between 70% and 80%, and turn on the humidity control equipment if necessary.

[0033] The above are the optimal temperature and humidity for the growth and reproduction of yeast and other microorganisms carried by the fermentation pit mud, which can provide an environment for the fermentation and aroma of tobacco leaves, thus improving the quality of tobacco leaves.

[0034] The beneficial effects of this invention are as follows:

[0035] This invention discloses a cellar fermentation method for improving the sensory quality of cigar tobacco leaves. By fermenting the tobacco leaves in a cellar environment, slow chemical changes occur inside the tobacco leaves. At the same time, the rich microorganisms in the soil come into contact with the tobacco leaves, accelerating the chemical change process. Fermenting the tobacco leaves in a cellar with a constant temperature all year round balances the flavor, improves maturity, enhances smoking quality, improves the basic quality of the raw materials, and brings out the characteristics of the raw materials. The fermented cigars have a mellow aroma, a sweet and slightly bitter taste, and a long aftertaste.

[0036] The flavor medium of this invention plays a supporting and breathable role in the fermentation process, avoiding the strong accumulation and compression of tobacco leaves that is unavoidable in traditional fermentation, improving the homogenization of fermentation, increasing the surface area of ​​tobacco leaves in contact with the environment, accelerating heat exchange, and facilitating the removal of impurities.

[0037] This invention pioneered the use of baijiu cellar mud in cigar tobacco fermentation, and can screen out microorganisms suitable for cigar tobacco fermentation.

[0038] This invention eliminates the need for turning the compost pile during the entire fermentation process, saving a significant amount of labor. Detailed Implementation

[0039] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be described in detail below. Obviously, the described embodiments are merely some embodiments of this invention, and not all embodiments. Based on the embodiments of this invention, all other implementation methods obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0040] In any embodiment, a cellar fermentation method for improving the sensory quality of cigar tobacco leaves according to the present invention includes:

[0041] When the fermentation medium is a flavor medium, the following steps are included:

[0042] Leave a space of about 100 square meters in the middle of the cellar, bury the large wine jar entirely in the mud, leaving only the mouth of the jar exposed. Place a layer of flavoring medium about 2 cm thick at the bottom of the jar, then place sesame sheets on top, followed by about 25 kg of tobacco leaves. Cover the tobacco leaves with another layer of sesame sheets, then another layer of flavoring medium, then another layer of sesame sheets, and so on, repeating this process for four layers of tobacco leaves, totaling 100 kg. Cover the top layer of tobacco leaves with another layer of sesame sheets, then another layer of flavoring medium, and finally another layer of sesame sheets. Compact the mixture, cover the jar, and allow it to ferment in the cellar. Depending on the quality of the tobacco leaves, the fermentation time is between 10 and 30 days.

[0043] When the fermentation medium is baijiu cellar mud, the following steps are included:

[0044] Using 200 kg of tobacco leaves as a unit, each fermentation chamber holds two units of tobacco leaves. A breathable soft cloth is laid flat under the tobacco leaves. The destemmed and peeled tobacco leaves are then stacked on the cloth, each stack 10 cm high. The first layer of tobacco leaves is arranged horizontally, and the second layer forms a 90-degree angle with the first layer. This stacking continues until 200 kg is filled. The soft cloth is then lifted to completely wrap the tobacco leaves. Baijiu (Chinese liquor) cellar mud is poured over the wrapped tobacco pile, completely sealing the soft cloth. The bottom of the pile is compacted with cellar mud to prevent air leakage. Another layer of soft cloth is then placed on top of the cellar mud, ensuring it completely covers the mud. The cloth is moistened with distilled water to prevent the cellar mud from cracking. Fermentation time ranges from 15 to 40 days, depending on the quality of the tobacco leaves.

[0045] Comparative example:

[0046] 1. Pile fermentation

[0047] The method involves rehydrating tobacco leaves to a high moisture content and piling them into a heap of about 2,000 kilograms. Under high temperature and humidity conditions, the chemical components inside the tobacco leaves undergo transfer and transformation, thereby improving the sensory quality and processing characteristics of the tobacco leaves.

[0048] 2. Fermentation in wooden barrels

[0049] After the tobacco leaves are moistened and rehydrated, they are placed in oak barrels and then sent to a fermentation chamber with a specific temperature and humidity for about 30 days to ferment, which helps to improve the quality of cigar tobacco leaves.

[0050] In the above methods, the tobacco leaves are tightly packed together during fermentation, making it difficult for the impurities generated during fermentation to be released. The tobacco leaves absorb these impurities a second time, which affects the fermentation effect. Furthermore, the contact area between the tobacco leaves varies, making it difficult to control the core temperature and ensure the homogenization of fermentation. A lot of manual turning is required. In addition, practice has shown that the large amount of water added to accelerate the fermentation process increases the bitterness of the tobacco leaves.

[0051] The sensory evaluation results of the embodiments and comparative examples of this invention are shown in the table below:

[0052] Table 1. Evaluation of samples taken from domestically produced cigar tobacco leaves after cellar fermentation.

[0053]

[0054]

[0055] The sensory evaluation results show that the sensory quality of domestic cigar tobacco leaves is improved after fermentation. However, the effect is more obvious after the two cellar fermentation techniques are used. The aroma and cleanliness of the tobacco leaves are improved, the irritation and off-flavors are reduced, and the smoothness and oral comfort are improved.

[0056] The chemical analysis results of the embodiments and comparative examples of the present invention are shown in the table below:

[0057] Table 2 Results of Tobacco Chemical Composition Test

[0058]

[0059] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims. It should also be noted that the various specific technical features described in the above embodiments can be combined in any suitable manner without contradiction. To avoid unnecessary repetition, the present invention will not describe the various possible combinations separately. Furthermore, various different embodiments of the present invention can also be arbitrarily combined, as long as they do not violate the spirit of the present invention, they should also be considered as the content disclosed in the present invention.

Claims

1. A cellar fermentation method for improving the sensory quality of cigar tobacco leaves, characterized in that, This includes the construction of the cellar site and the cellar fermentation process; When the fermentation medium is a flavor medium, the following steps are included: The large wine jar is buried entirely in the cellar mud, leaving only the mouth of the jar exposed. A layer of flavoring medium is laid at the bottom of the jar, followed by sesame sheets, then tobacco leaves, then another layer of sesame sheets, then another layer of flavoring medium, then another layer of sesame sheets, and so on, for a total of four layers of tobacco leaves. The top layer of tobacco leaves is also covered with a layer of sesame sheets, then another layer of flavoring medium, and finally another layer of sesame sheets. After compacting the mixture, the jar is covered and fermented in a cellar. The fermentation time is 10-30 days, depending on the quality of the tobacco leaves. The flavor medium includes one or more of the following: liquor lees, wintergreen gum, tea, and sawdust; When the fermentation medium is baijiu cellar mud, the following steps are included: Lay a breathable soft cloth flat under the tobacco leaves. Stack the destemmed and peeled tobacco leaves on the cloth, 10 cm high per stack. The first layer of tobacco leaves is arranged horizontally, and the second layer is at a 90° angle to the first layer. Continue stacking in this manner until 200 kg is covered. Pull up the cloth to completely wrap the tobacco leaves. Pour baijiu cellar mud over the wrapped tobacco pile, completely seal the cloth, and compact the bottom of the pile with cellar mud. Cover the mud with another layer of soft cloth and moisten it with distilled water. Depending on the quality of the tobacco leaves, the fermentation time is 15-40 days.

2. The cellar fermentation method for improving the sensory quality of cigar tobacco leaves as described in claim 1, characterized in that, The construction of the cellar site includes the following procedures: Cellar location: The top of the cellar is no less than 1 meter above the ground, the cellar height is 3 meters, and the area is no less than 300 square meters; Cellar walls: Waterproofing treatment is applied to the four walls, top and bottom of the cellar, and thermal insulation coating is applied to all six sides of the walls; Mud pit: A 1-meter-high, 3-meter-wide, and 5-meter-long pit is built against the wall of the cellar using bricks. The pit is lined with bricks on all sides and at the bottom. It is used to store and cultivate the mud. The fermented mud is returned to the pit for recycling. Fresh yellow mud is added to the mud regularly to cultivate new mud. Fermentation rooms: Five consecutive fermentation rooms are built on each side of the cellar, separated by bricks, with a layer of bricks laid at the bottom; each fermentation room is 4 meters long and 4 meters wide, with the height of the wall top as high as the wall top. Cellar door: Made of pine or oak, with a buffer zone in front of the cellar door, the buffer zone having a separate layer of insulation material; Cellar ventilation: Fresh air supply to the cellar should reach 1-2 times per hour; ventilation ducts should be installed in the cellar hall and fermentation room; Cellar interior lighting: Cold light sources or low-power incandescent lamps should be used inside the cellar.

3. The cellar fermentation method for improving the sensory quality of cigar tobacco leaves as described in claim 1, characterized in that, When the fermentation medium is a flavor medium, the thickness of the flavor medium is 2 cm, and the weight of a single layer of tobacco leaves is 25 kg.

4. The cellar fermentation method for improving the sensory quality of cigar tobacco leaves as described in claim 1, characterized in that, The temperature inside the cellar is maintained at 10-18℃ and the humidity at 70%-80%. The humidity control equipment is turned on when necessary.

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