A dry-process reconstituted sheet and its preparation method

Abstract

This application discloses a method for preparing a dry-process reconstituted sheet, comprising the following steps: S1. Dry-processing and defibrillating mixed fibers and air-forming them into a base sheet; wherein the mixed fibers are obtained by mixing paper-making tobacco sheets with one or both of fluff pulp fiberboard and hardwood fiberboard; S2. Evenly mixing a first adhesive, a first tobacco powder, and water to obtain a spraying liquid; S3. Evenly mixing a second adhesive, a second tobacco powder, water, an atomizer, and a flavoring agent to obtain a coating liquid; S4. Spraying the spraying liquid onto both sides of the base sheet and drying to obtain a sprayed base sheet; S5. Applying the coating liquid to one side of the sprayed base sheet, drying to a first moisture content, rolling, and drying again to a second moisture content to obtain a dry-process reconstituted sheet; wherein steps S1 to S3 can be performed in any order. This application also provides a dry-process reconstituted sheet. The preparation method provided in this application can effectively increase the tensile strength of the dry-process reconstituted sheet and improve the smoking quality.

Description

Technical Field

[0001] The present application relates to the field of tobacco technology, and in particular to a dry-process reconstituted sheet and a preparation method thereof. Background Art

[0002] Heated tobacco products (HTPs) heat tobacco to temperatures around 300-350°C without burning it. Within this heating range, the atomizer synergistically releases nicotine and other flavoring substances from the tobacco, allowing consumers to inhale for a physiological sense of satisfaction. Because the tobacco isn't burned, the smoke produced by traditional cigarettes contains 90-95% fewer harmful substances. Therefore, HTPs have been a key R&D focus for tobacco giants both domestically and internationally in recent years, and represent the future of tobacco products.

[0003] Tobacco flakes, also known as reconstituted or homogenized tobacco, are made by processing tobacco leaf fragments, tobacco dust, and tobacco stems, adding adhesives and other additives, and then drying them to create a sheet product with properties similar to or superior to those of natural tobacco. Dry-processed tobacco flakes, developed using airflow forming technology, are a new, environmentally friendly tobacco flake. Their loose structure and excellent filling properties greatly improve their adaptability for rolling and packaging. However, dry-processed tobacco flakes also have drawbacks such as low tensile strength, easy fragmentation, low spray adhesion, limited atomization, a high proportion of external fibers, and a strong woody aroma that lacks the natural tobacco flavor. Summary of the Invention

[0004] In order to solve the above technical problems, the first object of the present invention is to provide a method for preparing dry-process reconstituted flakes; the second object of the present invention is to provide dry-process reconstituted flakes prepared by the above preparation method; the preparation method provided in this application can effectively improve the tensile strength of the dry-process reconstituted flakes, reduce breakage, have excellent physical processing properties, and can increase the spray adhesion rate, improve the atomization effect and improve the suction quality, with sufficient smoke volume and good sensory suction quality.

[0005] The technical solutions provided by the present invention are as follows:

[0006] A method for preparing a dry-process reconstituted sheet comprises the following steps:

[0007] S1. Dry-fibering and air-forming the mixed fiber into a base sheet; wherein the mixed fiber is obtained by mixing paper-making tobacco sheets with one or two of fluff pulp fiberboard and hardwood fiberboard;

[0008] S2, mixing the first adhesive, the first smoke powder and water to obtain a spray liquid;

[0009] S3, mixing the second adhesive, the second smoke powder, water, the atomizer and the flavoring material to obtain a coating liquid;

[0010] S4, spraying the spraying liquid on both sides of the substrate, and drying to obtain a sprayed substrate;

[0011] S5, coating the coating liquid on one side of the spray-coated substrate, drying to a first moisture content, rolling, and drying again to a second moisture content to obtain a dry-process reconstituted sheet;

[0012] There is no order restriction for steps S1 to S3.

[0013] Preferably, the mixed fibers are composed of the following mass ratios:

[0014] Papermaking tobacco sheet: fluff pulp fiberboard (3-3.5): (1-2), or,

[0015] Papermaking tobacco sheet: hardwood fiberboard (3-3.5): (1-2), or,

[0016] Papermaking tobacco sheets: fluff pulp fiberboard: hardwood fiberboard (3-3.5): (0.5-1): (0.5-1).

[0017] Preferably, step S4 specifically comprises: spraying the spraying liquid on one side of the substrate, drying, turning the substrate over and spraying the other side, and drying again; the drying temperature is 80-105°C.

[0018] Preferably, step S5 is specifically as follows: coating the coating liquid on one side of the spray substrate with a coating thickness of 0.3-0.35 mm, drying at 80-100° C. to a moisture content of 25-30%, then rolling the material to a thickness of 0.18-0.2 mm, and drying at 80-100° C. to a moisture content of 10-12%.

[0019] Preferably, after the coating liquid is applied, the material is dried by electromagnetic heating to a moisture content of 25-30%;

[0020] After rolling, hot air is used to dry the product until the moisture content is 10-12%.

[0021] Preferably, the first tobacco powder and the second tobacco powder are independently selected from tobacco leaf fragments, tobacco dust, tobacco stems, etc. after threshing and redrying, or a combination thereof; and the particle size of the first tobacco powder and the second tobacco powder is 300-500 mesh;

[0022] The first adhesive and the second adhesive are independently selected from a mixture of guar gum and xanthan gum in a mass ratio of 1:(0.5-1);

[0023] The atomizer is a mixture of glycerol, propylene glycol and ethanol in a mass ratio of (10-15): (2-5): (0.5-1);

[0024] The flavoring substance is tobacco extract concentrate with a solid content of 30-35%.

[0025] Preferably, the mass ratio of the first adhesive, the first smoke powder and water is 1:(1-2):(50-60), and the mixing temperature is 50-60°C;

[0026] The mass ratio of the second adhesive, the second smoke powder, water, the atomizer and the flavoring substance is 1: (30-35): (80-100): (10-12): (8-10), and the mixing temperature is 50-60°C.

[0027] Preferably, during airflow forming, the aperture of the forming net is 150-200 meshes.

[0028] Preferably, the dry defibration is specifically to mechanically crush the mixed fibers;

[0029] The base sheet is 30-40g / m 2 .

[0030] A dry-process reconstituted sheet obtained by any of the above-mentioned preparation methods.

[0031] The present application first provides a preparation method of a dry-process reconstituted sheet, comprising the following steps: S1, dry-fiberizing and air-forming mixed fibers into a base sheet; wherein the mixed fibers are obtained by mixing paper-making tobacco sheets with one or two of fluff pulp fiberboard and hardwood fiberboard; S2, mixing a first adhesive, a first tobacco powder and water to obtain a spray liquid; S3, mixing a second adhesive, a second tobacco powder, water, an atomizer and a flavoring substance to obtain a coating liquid; S4, spraying the spray liquid on both sides of the base sheet, drying to obtain a sprayed base sheet; S5, coating the coating liquid on one side of the sprayed base sheet, drying to a first moisture content, rolling, and drying again to a second moisture content to obtain a dry-process reconstituted sheet; wherein, there is no order restriction for steps S1 to S3. The preparation method provided in this application can effectively improve the tensile strength of the dry-process reconstructed sheet, reduce breakage, have excellent physical processing properties, and can increase the spray adhesion rate, improve the atomization effect and improve the suction quality, with sufficient smoke volume and good sensory suction quality.

[0032] Specifically, the solution of this application has the following beneficial effects:

[0033] 1. Use mixed external fibers to prepare the base sheet. The mixed external fibers must include paper-made tobacco flakes. Since the content of tobacco stem fibers and exogenous fibers in paper-made tobacco flakes is much higher than that in thick pulp tobacco flakes and roller-pressed tobacco flakes, using paper-made tobacco flakes can not only increase the tobacco content in the dry-made base sheet, but the fibers contained in paper-made tobacco flakes can also serve as the fiber skeleton of the dry-made base sheet. Then, one or two of fluff pulp fiberboard and hardwood fiberboard are selected and compounded to further ensure that the base sheet forms an exogenous fiber skeleton. Furthermore, mixing exogenous fibers with paper-made tobacco flakes as the main component can effectively reduce the content of exogenous fibers and improve the sensory smoking quality.

[0034] 2. The substrate is formed by spraying first. The spraying liquid can enhance the tensile strength of the substrate. The small amount of tobacco powder in the spraying liquid can fill the loose and porous substrate skeleton, forming a dense structure. This increases the strength while further increasing the tobacco content in the dry-process reconstituted sheet. Furthermore, the flavoring substance in the coating liquid is tobacco extract, which further increases the tobacco aroma components in the dry-process sheet and improves the smoking quality of the dry-process sheet.

[0035] 3. Rolling the slices can improve the internal density of the dry-process slices, further combine the base sheet skeleton with the tobacco components, and reduce the occurrence of powder loss or breakage while improving the tensile strength.

[0036] In the present application, dry defibration is preferably performed by mechanically crushing the mixed fibers, which can be achieved by using a supersonic airflow mill.

[0037] In the present application, the preferred flavoring substance is a tobacco extract concentrate with a solid content of 30-35%, and the tobacco raw materials for extraction and concentration can be tobacco leaves, tobacco stems and other materials known in the art.

[0038] In the present application, the first tobacco powder and the second tobacco powder can also be obtained by crushing raw materials known in the art, such as one or more of tobacco leaf fragments, tobacco dust, and tobacco stems after threshing and re-roasting.

[0039] In the present application, airflow forming can be realized by a forming machine well known in the art. After the fibers are broken up by a scattering roller, they enter a settling chamber. The fibers are protected by negative pressure at the bottom of the former and form substrates on a forming net. The whole process is mediated by air. The selection of different forming nets has a significant impact on the forming effect of dry process substrates. Due to the negative pressure forming method, if the mesh size is less than 100 mesh, small gaps will be formed on the substrate surface, affecting the strength. If the mesh size is greater than 250 mesh, the substrate forming effect is not good and is very fluffy. Therefore, during the preferred airflow forming of the present application, the aperture of the forming net is 150-200 mesh. DETAILED DESCRIPTION

[0040] In order to help those skilled in the art better understand the technical solutions in this application, the technical solutions in the embodiments of this application will be clearly and completely described below. Obviously, the embodiments described are only part of the embodiments of this application, not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without making any creative efforts shall fall within the scope of protection of this application.

[0041] Example 1

[0042] A method for preparing a dry-process reconstituted sheet comprises the following steps:

[0043] S1. Papermaking tobacco sheets and fluff pulp fiberboard are mechanically crushed in a mass ratio of 3:1 to form a mixed outer fiber. The base sheet is air-formed to form a base sheet with a basis weight of 30g / m 2 .

[0044] S2. Weigh 1 kg of guar gum and 0.5 kg of xanthan gum, mix them evenly, add 1.5 kg of smoke powder with a particle size of 400 mesh, add 75 kg of hot water at a temperature of 50° C., and stir mechanically until the mixture is evenly mixed to obtain a spray liquid.

[0045] S3. Weigh 1 kg of guar gum and 0.5 kg of xanthan gum, mix them evenly, add 45 kg of tobacco powder with a particle size of 400 mesh, add 150 kg of hot water at a temperature of 50°C, add 15 kg of atomizer (glycerol: propylene glycol: ethanol mass ratio of 10:2:0.5), add 15 kg of tobacco extract concentrate (solid content 30%), stir mechanically until mixed evenly, and obtain a coating liquid.

[0046] S4. Spray the coating liquid evenly on the surface of the substrate, spraying once on the front side and drying once, spraying once on the back side and drying once, and drying in an oven at 100°C. After testing, the tensile strength of the sprayed substrate is 0.2-0.3KN / m.

[0047] S5. The coating liquid is coated on one side of the sprayed substrate with a coating thickness of 0.3-0.35 mm. The material is then dried using electromagnetic heating at a drying temperature of 100°C. When the moisture content after drying is 25%, the sheet is sent to a roller press. After rolling, the material thickness is 0.18-0.2 mm. The material is dried using hot air at 100°C to a moisture content of 12% to obtain a dry-process reconstructed sheet.

[0048] Example 2

[0049] A method for preparing a dry-process reconstituted sheet comprises the following steps:

[0050] S1. Papermaking tobacco sheets and broadleaf wood fiberboard are mixed in a mass ratio of 3:1 and mechanically crushed to form a base sheet with a basis weight of 30g / m 2 .

[0051] S2. Weigh 1 kg of guar gum and 0.5 kg of xanthan gum, mix them evenly, add 1.5 kg of 500-mesh smoke powder, add 75 kg of 50° C. hot water, and stir mechanically until the mixture is evenly mixed to obtain a spray solution.

[0052] S3. Weigh 1 kg of guar gum and 0.5 kg of xanthan gum, mix them evenly, add 45 kg of tobacco powder with a particle size of 500 mesh, add 150 kg of hot water at a temperature of 50°C, add 15 kg of atomizer (glycerol: propylene glycol: ethanol mass ratio of 10:2:0.5), add 15 kg of tobacco extract concentrate (solid content 30%), stir mechanically until mixed evenly, and obtain a coating liquid.

[0053] S4. Spray the coating liquid evenly on the surface of the substrate, spraying once on the front side and drying once, spraying once on the back side and drying once, and drying in an oven at 100°C. After testing, the tensile strength of the sprayed substrate is 0.2-0.3KN / m.

[0054] S5. The coating liquid is coated on one side of the sprayed substrate with a coating thickness of 0.3-0.35 mm. The material is then dried using electromagnetic heating at 80°C. When the moisture content after drying is 25%, the sheet is sent to a roller press. After rolling, the material thickness is 0.18-0.2 mm. The material is dried using hot air at 80°C to a moisture content of 10-12%, thereby obtaining a dry-process reconstituted sheet.

[0055] Example 3

[0056] A method for preparing a dry-process reconstituted sheet comprises the following steps:

[0057] S1. Papermaking tobacco sheets, fluff pulp fiberboard and hardwood fiberboard are mixed with external fibers in a mass ratio of 3:0.5:0.5, and air-formed to produce a base sheet with a basis weight of 30 g / m 2 .

[0058] S2. Weigh 1 kg of guar gum and 0.5 kg of xanthan gum, mix them evenly, add 1.5 kg of 300-mesh smoke powder, add 75 kg of 50° C. hot water, and stir mechanically until the mixture is evenly mixed to obtain a spray liquid.

[0059] S3. Weigh 1 kg of guar gum and 0.5 kg of xanthan gum, mix them evenly, add 45 kg of tobacco powder with a particle size of 300 mesh, add 150 kg of hot water at a temperature of 50°C, add 15 kg of atomizer (glycerol: propylene glycol: ethanol mass ratio of 10:2:0.5), add 15 kg of tobacco extract concentrate (solid content 35%), stir mechanically until mixed evenly, and obtain a coating liquid.

[0060] S4. Spray the coating liquid evenly on the surface of the substrate. Spray once on the front side and dry once, spray once on the back side and dry once. Use an oven to dry at a temperature of 100°C. The tensile strength of the sprayed substrate is tested to be 0.2-0.3KN / m.

[0061] S5. Apply the coating liquid to one side of the spray-coated substrate to a thickness of 0.3-0.35 mm. Then, use electromagnetic heating to dry the material at 95°C. When the moisture content after drying is 25%, send the sheet to a roller press. After rolling, the material thickness is 0.18-0.2 mm. Use hot air drying at 100°C to a moisture content of 12% to obtain a dry-process reconstituted sheet. Then peel it off.

[0062] Comparative Example 1

[0063] Compared with Example 1, in Comparative Example 1, no papermaking tobacco flakes were added to the mixed external fibers, and only fluff pulp fiberboard was used for mechanical crushing and airflow forming. The remaining steps were consistent with Example 1 to obtain dry-process reconstituted flakes.

[0064] Comparative Example 2

[0065] Comparative Example 2 Compared with Example 1, the tobacco extract concentrate was not added to the coating liquid, and its weight was replaced by water. The remaining steps were the same as those in Example 1 to obtain a dry-process reconstituted sheet.

[0066] Comparative Example 3

[0067] Comparative Example 3 Compared with Example 1, 1.5 kg of guar gum was weighed, and the addition of 0.5 kg of xanthan gum was removed. The remaining steps were consistent with Example 1 to obtain dry-process reconstituted flakes.

[0068] Comparative Example 4

[0069] Compared with Example 1, Comparative Example 4 adopts the method of spraying four times on both sides without coating to obtain a dry-process reconstructed sheet.

[0070] Comparative Example 5

[0071] Compared with Example 1, Comparative Example 5 adopts the method of spraying 8 times on both sides without coating to obtain a dry-process reconstructed sheet.

[0072] The physical and chemical indicators of the dry-process reconstituted sheets prepared in Examples 1-3 and Comparative Examples 1-5 are shown in Table 1. Professional tasters conducted sensory evaluation of the products according to the national standard (sensory technical requirements) GB5606.4-2005. The sensory evaluation score table is shown in Table 2, and the overall evaluation description is shown in Table 3.

[0073] Table 1 Physical and chemical indicators of dry-process reconstructed sheets

[0074]

[0075] Table 2 Sensory evaluation scores of dry-process reconstituted flakes

[0076]

[0077] Table 3 Sensory evaluation scores of dry-process reconstituted flakes

[0078]

[0079] From the results in Tables 1 to 3, we can see that:

[0080] In Examples 1-3, the different ratios of paper-made tobacco flakes to fluff pulp fiberboard and hardwood fiberboard in the mixed external fibers had little effect on tensile strength and crushing rate. However, the different mixed external fibers had a slight impact on the sensory evaluation of the dry-process reconstituted flakes, and the combination of three external fibers was superior to that of two external fibers. Comparative Example 1, in which no paper-made tobacco flakes were added and only fluff pulp fiberboard was used for mechanical crushing, improved the tensile strength and crushing rate of the flakes. However, the sensory evaluation was significantly affected, and the aroma was unpleasant, with a woody odor and a slight smell of other things.

[0081] Comparative Example 2 is compared with Example 1. No tobacco extract concentrate is added to the coating liquid. The tensile strength and crushing rate of the slices do not change significantly. However, the sensory evaluation is greatly affected. The aroma is unpleasant, has a slight woody smell, is weak in strength, and has a lot of foreign smells.

[0082] Comparative Example 3 is compared with Example 1. The use of single guar gum results in a significant decrease in the tensile strength of the slices and a significant increase in the crushing rate. The sensory evaluation is also affected, with a slight woody smell and a slight mixed smell.

[0083] Comparative Example 4 is compared with Example 1. It adopts the method of spraying 4 times on both sides without coating. The tensile strength of the sheet is significantly reduced, the breakage is significantly increased, the atomizer content is low, the comprehensive suction score is low, the aroma is uncomfortable, the wood smell is heavy, the miscellaneous smell is heavy, the strength is small, and the amount of smoke is small.

[0084] Comparative Example 5 is compared with Example 1. It adopts the method of 8 times of positive and negative spraying without coating. Compared with Comparative Example 4, the tensile strength and crushing of the sheet are slightly improved, but it is also significantly inferior to Examples 1-3. The atomizer content is low, the inhalation aroma is uncomfortable, the wood smell is heavier, the miscellaneous smell is slightly heavier, the strength is slightly smaller, and the amount of smoke is small.

[0085] It can be seen that this application adopts the form of spraying first and then coating. One coating load rate may require dozens of spraying times to achieve the same load effect, and avoids the situation where a large amount of spraying material is wasted, and can achieve better tensile strength and suction quality.

[0086] In Examples 1-3 of the present application, the substrate prepared in step S1 has no requirement for tensile strength. After the tensile strength of the sprayed substrate obtained after the treatment in step S4 is increased to 0.2-0.3 KN / m, the fiber skeleton strength of the sprayed substrate can be better exerted, and then the coating operation in step S5 is performed. The tensile strength of the obtained dry-process recycled thin sheet can reach more than 0.55 KN / m, while the tensile strength of comparative examples 4-5 using multiple spraying can only reach a maximum of 0.376 KN / m.

[0087] The above description of the disclosed embodiments is intended to enable one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be readily apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not intended to be limited to the embodiments shown herein, but rather to be construed in the widest possible manner consistent with the principles and novel features disclosed herein.

Claims

1. A method for preparing a dry-process reconstituted sheet, characterized in that: The following steps are involved: S1, dry-fibering the mixed fiber and air-forming it into a substrate; The mixed fibers are composed of the following mass ratios: paper-making tobacco sheets: fluff pulp fiberboard (3-3.5): (1-2), or, paper-making tobacco sheets: hardwood fiberboard (3-3.5): (1-2), or, paper-making tobacco sheets: fluff pulp fiberboard: hardwood fiberboard (3-3.5): (0.5-1): (0.5-1); S2, mixing the first adhesive, the first smoke powder and water to obtain a spray liquid; S3, mixing the second adhesive, the second smoke powder, water, the atomizer and the flavoring material to obtain a coating liquid; S4, spraying the spraying liquid on both sides of the substrate, and drying to obtain a sprayed substrate; S5, applying the coating liquid to one side of the spray-coated substrate to a coating thickness of 0.3-0.35 mm, drying to a first moisture content, rolling, and drying again to a second moisture content to obtain a dry-process reconstituted sheet; There is no order restriction for steps S1 to S3; The first adhesive and the second adhesive are independently selected from a mixture of guar gum and xanthan gum in a mass ratio of 1:(0.5-1); The flavoring substance is tobacco extract concentrate with a solid content of 30-35%.

2. The preparation method according to claim 1, characterized in that Step S4 specifically comprises: spraying the spraying liquid on one side of the substrate, drying, turning the substrate over and spraying the other side, and drying again; the drying temperature is 80-105°C.

3. The preparation method according to claim 1, characterized in that Step S5 is specifically as follows: coating the coating liquid on one side of the spray substrate, drying at 80-100°C to a moisture content of 25-30%, then rolling to a material thickness of 0.18-0.2mm, and drying at 80-100°C to a moisture content of 10-12%.

4. The preparation method according to claim 3, characterized in that After the coating liquid is applied, the material is dried by electromagnetic heating until the moisture content is 25-30%; After rolling, hot air is used to dry the product until the moisture content is 10-12%.

5. The preparation method according to claim 1, characterized in that The particle size of the first smoke powder and the second smoke powder is 300-500 mesh; The atomizer is a mixture of glycerol, propylene glycol and ethanol in a mass ratio of (10-15): (2-5): (0.5-1).

6. The preparation method according to any one of claims 1 or 5, characterized in that The mass ratio of the first adhesive, the first smoke powder and water is 1: (1-2): (50-60), and the mixing temperature is 50-60°C; The mass ratio of the second adhesive, the second smoke powder, water, the atomizer and the flavoring substance is 1: (30-35): (80-100): (10-12): (8-10), and the mixing temperature is 50-60°C.

7. The preparation method according to claim 1, characterized in that During airflow forming, the aperture of the forming mesh is 150-200 meshes.

8. The preparation method according to claim 1, characterized in that Dry fiber defibrination specifically involves mechanically crushing the mixed fibers; The base sheet is 30-40g / m 2 .

9. The dry-process reconstituted sheet obtained by the preparation method according to any one of claims 1 to 8.

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