Method for anaerobic fermentation of cigar tobacco leaves through pottery jar

Abstract

The invention discloses a method for anaerobic fermentation of cigar tobacco leaves through a pottery jar, which comprises the following steps: selecting cigar tobacco leaves and the pottery jar, tidily paving the cigar tobacco leaves and putting the cigar tobacco leaves into the pottery jar, putting a temperature sensor between the cigar tobacco leaves in the pottery jar when the cigar tobacco leaves are put into the middle position of the pottery jar, covering a jar cover after the pottery jar is filled with the cigar tobacco leaves, the method comprises the following steps: putting a pottery jar into a jar cover, sealing a gap between the pottery jar and the jar cover, performing temperature-controlled fermentation on the pottery jar, injecting carbon dioxide gas into the jar body through a middle two-way gas valve to perform temperature control when the temperature in the jar body exceeds a limited temperature in the fermentation process, and performing horizontal balance on cigar tobacco leaves after fermentation is finished. A stable microenvironment is maintained in the long-time fermentation process of cigar tobacco leaves, the adverse effect of external environment fluctuation on the fermentation process is effectively avoided, the two-way valve is arranged to provide a stable anaerobic fermentation environment for the tobacco leaves, meanwhile, temperature regulation and control can be achieved, excessive volatilization of flavor substances caused by long-time high temperature is avoided, and the quality of the cigar tobacco leaves is improved. And the quality of the cigar tobacco leaves is improved.

Description

Technical Field

[0001] The invention relates to a cigar tobacco leaf fermentation process, and more particularly to a method for anaerobic fermentation of cigar tobacco leaves through a ceramic pot. Background Art

[0002] Unfermented cigar tobacco leaves have problems such as strong green smell, insufficient aroma, strong irritation, strong bitterness, and strong strength. In terms of appearance, there will be problems such as uneven color, strong variegated and green spots, poor toughness, easy to break, and easy to mold. These problems will directly affect the cigar rolling process and the quality of the finished cigars. Therefore, a good fermentation process is of great significance to the improvement of cigar quality and the effective use of tobacco raw materials.

[0003] The fermentation methods of cigar tobacco leaves are mainly divided into natural aging and artificial fermentation. Natural aging refers to a method of natural fermentation for a long time at appropriate temperature and humidity, but the oxygen in the air will cause oxidative stress to the microorganisms in the tobacco leaves. This oxidative stress will not only lead to the oxidation of macromolecules such as lipids, but also generate bad odors, thereby reducing the flavor quality of the tobacco leaves. It may also trigger the production of reactive oxygen (ROS), further promoting the increase of harmful byproducts such as ammonia substances and nitrates, resulting in a significant increase in the irritation of tobacco leaves, making the cigar smoking experience unpleasant. In addition, long-term exposure of tobacco leaves to high temperature, high humidity aerobic environments will also lead to mold growth, while aggravating the formation of variegated colors and blue spots, thereby affecting the overall quality of the tobacco leaves. Artificial fermentation refers to human intervention in the fermentation process, which accelerates the fermentation process and improves the fermentation quality of the product by fermenting under specific environmental, temperature, and humidity conditions.

[0004] Chinese invention patent application document CN117694586A discloses a method for making cigar-flavored flat tobacco and a tobacco product. The method reduces impurities and increases sweetness through pretreatment, mixing, adding fermentation medium, anaerobic fermentation, and shredding balance steps, but the method has the problem of a long fermentation cycle.

[0005] Chinese invention patent application document CN117958480A discloses a method for pre-fermentation of cigar tobacco leaves. This method relies on stacking and fermentation in a combined anaerobic and aerobic manner to reduce the problems of blue spots, variegated colors and unbalanced chemical composition ratios in tobacco leaves. However, this method requires frequent turning of the pile to ensure uniform fermentation of the tobacco leaves, which increases the production costs of the enterprise.

[0006] As the tobacco industry's demand for high-quality products continues to grow, aerobically fermented cigars have problems such as poor flavor, strong irritation, heavy odor, and uneven color. An efficient and economical fermentation process is urgently needed to solve these problems. Summary of the invention

[0007] The present invention overcomes the shortcomings of the prior art and provides an implementation method for anaerobically fermenting cigar tobacco leaves through a ceramic jar, in the hope of solving the problems of poor flavor, strong irritation, heavy impurities and uneven color of cigar tobacco leaves after fermentation in the prior art.

[0008] In order to solve the above technical problems, one embodiment of the present invention adopts the following technical solution:

[0009] A method for anaerobic fermentation of cigar tobacco leaves using a ceramic jar comprises the following steps:

[0010] Step (1), selecting cigar tobacco leaves that have not been tempered for use, and selecting a ceramic jar for use, wherein the ceramic jar has a middle two-way gas valve in the middle of the jar body, and the jar cover has a jar cover two-way gas valve, and the two-way gas valve can switch between output, input and closed states;

[0011] Step (2), laying the cigar tobacco leaves selected in step (1) neatly and placing them in a ceramic jar, placing a temperature sensor between the cigar tobacco leaves in the ceramic jar when the cigar tobacco leaves are placed in the middle of the ceramic jar, covering the ceramic jar with a lid after the cigar tobacco leaves are filled, and sealing the gap between the ceramic jar and the lid;

[0012] Step (3), placing the ceramic jar containing cigar tobacco leaves obtained in step (2) into a fermentation room for temperature-controlled fermentation, during which the two-way gas valve on the jar cover is in an output state, and the middle two-way gas valve is in a closed state. During the temperature-controlled fermentation process, when the temperature inside the jar exceeds the set temperature in the fermentation room, carbon dioxide gas is injected into the jar through the middle two-way gas valve to control the temperature, so that the temperature inside the jar drops below the set temperature in the fermentation room;

[0013] Step (4), performing moisture balance on the cigar tobacco leaves obtained after the fermentation in step (3).

[0014] Further: in step (3), the humidity in the fermentation room is 60%-100%.

[0015] Further: in step (3), the humidity in the fermentation room is 80±5%.

[0016] Furthermore: the temperature-controlled fermentation in step (3) is to control the temperature in the fermentation room to 30-47°C and ferment at this temperature.

[0017] Further: the temperature in the fermentation room is kept constant.

[0018] Further: the temperature-controlled fermentation is a three-stage temperature-variable fermentation, including a first stage fermentation of 15 days, a second stage fermentation of 15 days, and a third stage fermentation of 30 days;

[0019] The temperature of the fermentation room in the first stage is 40-50℃, the temperature of the fermentation room in the second stage is 35-40℃, and the temperature of the fermentation room in the third stage is 30-40℃.

[0020] Further: in step (3), the temperature of the fermentation room in the first stage is 47°C, the temperature of the fermentation room in the second stage is 40°C, and the temperature of the fermentation room in the third stage is 35°C.

[0021] Furthermore: when the temperature is controlled by carbon dioxide in step (3), the injection time of carbon dioxide is 15-45S.

[0022] Furthermore: during the moisture balance in step (4), the moisture content of the tobacco leaves is balanced to 18±1%.

[0023] Compared with the prior art, the present invention has at least the following beneficial effects: the present invention utilizes the excellent sealing performance of the ceramic pot to effectively isolate the external oxygen, maintain a stable microenvironment for the long-term fermentation process of the cigar tobacco, effectively avoid the adverse effects of external environmental fluctuations on the fermentation process, and ensure the stable and consistent quality of the fermented cigar tobacco; the setting of the two-way valve provides a stable anaerobic fermentation environment for the tobacco leaves while also achieving temperature control, avoiding excessive volatilization of flavor substances caused by long-term high temperature, effectively retaining the aroma components of the cigar tobacco leaves, ensuring balanced flavor, reducing the generation of common miscellaneous gases and odors, and making the aroma of the tobacco leaves more mellow. At the same time, the anaerobic fermentation of tobacco leaves in the ceramic pot does not require turning the pile, which also reduces labor costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 It is a schematic diagram of the structure of the pottery jar of the present invention;

[0025] Figure numerals: 1. two-way gas valve on the jar cover; 2. two-way gas valve in the middle; 3. temperature sensor. DETAILED DESCRIPTION

[0026] In order to make the purpose, technical solution and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0027] Example 1

[0028] A cylindrical pottery jar with a thick middle part and thin top and bottom is selected. The diameter of the bottom of the pottery jar is 1m, the diameter of the middle part is 1.2m, and the height is 1m. There is a middle two-way gas valve 2 in the middle of the pottery jar body, and a two-way gas valve 1 on the jar cover. The diameter of the two-way gas valve is 5cm, and the two-way gas valve can switch the output, input and closed states.

[0029] Select cigar tobacco leaves that have not been tempered and lay them neatly and flatly into a ceramic jar. When filling, lightly press the cigar tobacco leaves. When the cigar tobacco leaves are loaded into the middle of the ceramic jar, place a temperature sensor 3 between the cigar tobacco leaves in the ceramic jar. After the ceramic jar is filled with cigar tobacco leaves, cover the jar with a lid and seal the gap between the ceramic jar and the lid. Put the ceramic jar with cigar tobacco leaves into a fermentation room for fermentation. The fermentation cycle is 60 days, and the temperature of the fermentation room is controlled in the following time sequence to perform three-level temperature-variable fermentation:

[0030] The temperature of the fermentation room in the first stage is 47°C, the fermentation time is 15 days, and the humidity of the fermentation room is 80±5%; the temperature of the fermentation room in the second stage is 40°C, the fermentation time is 15 days, and the humidity of the fermentation room is 80±5%; the temperature of the fermentation room in the third stage is 35°C, the fermentation time is 30 days, and the humidity of the fermentation room is 80±5%; during the fermentation process, the middle two-way gas valve is closed, and the two-way gas valve on the jar cover is in the output state, so that the fermentation impurities inside the pottery jar can be discharged through the two-way gas valve on the jar cover, and external gas cannot enter the pottery jar; during the three-stage fermentation process, the temperature inside the pottery jar is monitored by a temperature sensor. When the temperature sensor shows that the temperature inside the pottery jar is When the temperature exceeds the set temperature in the fermentation room (the first stage exceeds 47°C, the second stage exceeds 40°C, and the third stage exceeds 35°C), carbon dioxide gas is injected into the jar body through the middle two-way gas valve to cool the inside of the jar body, so that the temperature of the tobacco leaves in the ceramic jar drops below the set temperature. At the same time, the two-way gas valve on the jar cover is kept in an open state so that carbon dioxide gas can be discharged. The carbon dioxide injection time is 30S. After the carbon dioxide injection is completed, the middle two-way gas valve is adjusted to a closed state. The injection of carbon dioxide can lower the temperature inside the ceramic jar, make the temperature distribution more even, and discharge the green impurities in the jar body, while maintaining the anaerobic environment of the ceramic jar.

[0031] After fermentation is completed, the tobacco leaves are taken out of the pottery jar and sprayed with an atomizing sprayer for 3 seconds. After moisture balance, the moisture content of the tobacco leaves is tested to reach 18±1%. The cigar tobacco leaves that have completed fermentation are then rolled into single-material cigarettes of uniform specifications for sensory evaluation and testing of the tobacco leaf mold rate.

[0032] Example 2

[0033] This embodiment is basically the same as embodiment 1, except that the three-stage variable temperature fermentation is changed to constant temperature fermentation, wherein the temperature of the fermentation room is 30°C, and during the fermentation process when the temperature in the pottery jar exceeds 30°C, carbon dioxide gas is injected for temperature control, and the temperature of the tobacco leaves in the pottery jar is controlled to 30°C.

[0034] Example 3

[0035] This embodiment is basically the same as embodiment 1, except that the three-stage variable temperature fermentation is changed to a constant temperature fermentation, wherein the temperature of the fermentation room is 35°C, and during the fermentation process when the temperature in the pottery jar exceeds 35°C, carbon dioxide gas is injected for temperature control, and the temperature of the tobacco leaves in the pottery jar is controlled to 35°C.

[0036] Example 4

[0037] This embodiment is basically the same as embodiment 1, except that the three-stage variable temperature fermentation is changed to constant temperature fermentation, wherein the temperature of the fermentation room is 40°C, and during the fermentation process when the temperature in the pottery jar exceeds 40°C, carbon dioxide gas is injected for temperature control, and the temperature of the tobacco leaves in the pottery jar is controlled to 40°C.

[0038] Example 5

[0039] This embodiment is basically the same as embodiment 1, except that the three-stage variable temperature fermentation is changed to a constant temperature fermentation, wherein the temperature of the fermentation room is 47°C, and during the fermentation process when the temperature in the pottery jar exceeds 47°C, carbon dioxide gas is injected for temperature control, and the temperature of the tobacco leaves in the pottery jar is controlled to 47°C.

[0040] Comparative Example 1

[0041] This embodiment is basically the same as Embodiment 1, except that: a two-way gas valve is not installed on the ceramic jar used, and when the temperature sensor detects that the temperature in the ceramic jar exceeds the set temperature in the fermentation room, the jar cover is opened and carbon dioxide is injected from the top jar opening to control the temperature.

[0042] Comparative Example 2

[0043] This embodiment is basically the same as the embodiment 1, except that: during the fermentation process, only the temperature of the fermentation room is changed, and when the temperature in the pottery jar exceeds the set temperature in the fermentation room, carbon dioxide temperature control is not performed.

[0044] Comparative Example 3

[0045] This embodiment is basically the same as the embodiment 1, except that the cigar tobacco leaves are directly placed in the fermentation room for aerobic fermentation, and the fermentation process adopts the three-stage variable temperature fermentation in the embodiment 1, without carbon dioxide temperature control.

[0046] The temperature, humidity and fermentation period in Examples 1-5 and Comparative Examples 1-3 are shown in Table 1:

[0047] Table 1 Temperature, humidity and fermentation cycle

[0048]

[0049]

[0050] The tobacco leaves after fermentation in Examples 1-8 were rolled into single-material cigarettes of uniform specifications, and sensory evaluation was performed by 10 sensory tasters from Sichuan China Tobacco Great Wall Cigar Factory. The sample fermented on day 0 was used as the benchmark and named as the original cigarette (all indicators were 5 points). The scores of the 10 tasters were summarized as the sensory evaluation score. The evaluation items included the mellowness, richness, irritation, sweetness, miscellaneous smell, aftertaste, and combustibility of the tobacco leaves. The evaluation results are shown in Table 2:

[0051] Table 2 Sensory evaluation results

[0052] Sample name Mellowness Richness Sweetness Irritant Miscellaneous gas Aftertaste Combustibility Original Tobacco 50.0 50.0 50.0 50.0 50.0 50.0 50.0 Example 1 72.0 70.6 69.0 65.0 64.8 66.0 64.0 Example 2 66.2 68.2 65.0 63.0 62.0 64.0 62.0 Example 3 65.9 64.5 68.0 59.0 61.8 62.6 63.0 Example 4 70.0 67.0 62.0 61.0 63.4 64.5 60.6 Example 5 69.0 71.0 61.0 58.4 64.2 59.0 58.4 Comparative Example 1 67.8 65.9 67.2 62.0 61.0 65.0 61.8 Comparative Example 2 64.2 65.5 61.9 57.3 62.5 61 62.8 Comparative Example 3 59.0 54.0 57.9 54.8 60.0 58.0 60.0

[0053] Among them: the score of each indicator is set from 1 to 10 points from the worst to the best;

[0054] The mellowness refers to the purity, harmony and softness of the aroma;

[0055] Sweetness refers to the sweetness that can be felt in the smoke and aftertaste;

[0056] Irritation refers to the slight or obvious irritation and discomfort caused by smoke to the senses;

[0057] Odor refers to the degree of unpleasant odor caused by smoke in people's senses;

[0058] Aftertaste refers to the lingering feeling and disadvantages left on the taste buds after smoke is expelled from the mouth and nose;

[0059] Burnability refers to the ability of a cigar to maintain a steady burn after being lit.

[0060] As can be seen from Table 2, the ceramic jar anaerobic fermentation (Examples 1-5, Comparative Examples 1-2) performed better than the aerobic fermentation (Comparative Example 3) in all quality indicators, indicating that anaerobic fermentation is more helpful in improving the aroma level, softness and persistence of the aftertaste of cigar tobacco leaves.

[0061] The ceramic jar of Comparative Example 1 does not use a two-way gas valve for carbon dioxide delivery and temperature control. Compared with Example 1, the scores of various performance indicators thereof are reduced, indicating that the installation of a two-way gas valve on the ceramic jar for carbon dioxide delivery and temperature control is beneficial to improving the fermentation effect of cigar tobacco leaves, thereby improving the sensory quality.

[0062] Comparative Example 2 used ceramic jars for anaerobic fermentation, but did not use carbon dioxide for temperature control. Compared with Example 1, the sensory quality of cigar tobacco leaves was significantly reduced, and was also significantly reduced compared with Comparative Example 1, indicating that carbon dioxide needs to be used for temperature control during anaerobic fermentation in ceramic jars.

[0063] Example 1 not only uses anaerobic fermentation in a pottery jar and carbon dioxide delivery temperature control, but also uses three-stage variable temperature fermentation, which has significant improvements in key flavor indicators such as mellowness, richness, sweetness, and aftertaste, indicating that the combination of installing a two-way gas valve on the pottery jar to input carbon dioxide temperature control, anaerobic fermentation, and three-stage variable temperature fermentation is more helpful to improve the aroma level, softness, and persistence of the aftertaste of cigar tobacco leaves. At the same time, it performs slightly better in reducing irritation and impurities. The anaerobic fermentation in the pottery jar helps to improve the cleanliness of the smoke and reduce unpleasant odors. Overall, the anaerobic fermentation in the pottery jar has a significant effect on reducing the impurities and irritation of cigar tobacco leaves and improving the richness of tobacco leaf flavor.

[0064] The results of the mildew rate test are shown in Table 3:

[0065] Table 3 Mildew rate test results

[0066]

[0067]

[0068] The tobacco leaf mildew rate is detected by weighing all fermented tobacco leaves of the corresponding embodiment to obtain the total weight of the tobacco leaves; taking out the mildewed tobacco leaves of the corresponding embodiment and weighing them to obtain the total weight of the mildewed tobacco leaves, that is, the tobacco leaf mildew rate = (total weight of mildewed tobacco leaves / total weight of tobacco leaves) × 100%.

[0069] Among them: Examples 1-5 and Comparative Examples 1-2 are all anaerobic fermentation in pottery jars, and the mildew rate of tobacco leaves is significantly lower than that of aerobic fermentation (Comparative Example 3), indicating that the anaerobic fermentation method of pottery jars can effectively reduce the probability of tobacco leaves mildewing in a high temperature and high humidity environment. Among them, the mildew rate of Example 1 is the lowest, indicating that the method of anaerobic three-stage variable temperature fermentation in pottery jars can further reduce the probability of tobacco leaves mildewing in a high temperature and high humidity environment.

[0070] The present invention is described herein with reference to the illustrative embodiments of the present invention, but it should be understood that those skilled in the art can design many other modifications and implementations, which will fall within the scope and spirit of the principles disclosed in this application. More specifically, within the scope disclosed in this application, multiple variations and improvements can be made to the components and / or layout of the subject combination layout. In addition to the variations and improvements made to the components and / or layout, other uses will also be obvious to those skilled in the art.

Claims

1. A method for anaerobic fermentation of cigar tobacco leaves using a ceramic jar, characterized in that: The following steps are involved: Step (1), selecting cigar tobacco leaves that have not been tempered for use, and selecting a ceramic jar for use, wherein the ceramic jar has a middle two-way gas valve in the middle of the jar body, and the jar cover has a jar cover two-way gas valve, and the two-way gas valve can switch between output, input and closed states; Step (2), laying the cigar tobacco leaves selected in step (1) neatly and placing them in a ceramic jar, placing a temperature sensor between the cigar tobacco leaves in the ceramic jar when the cigar tobacco leaves are placed in the middle of the ceramic jar, covering the ceramic jar with a lid after the cigar tobacco leaves are filled, and sealing the gap between the ceramic jar and the lid; Step (3), placing the ceramic jar containing cigar tobacco leaves obtained in step (2) into a fermentation room for temperature-controlled fermentation, during which the two-way gas valve on the jar cover is in an output state, and the middle two-way gas valve is in a closed state. During the temperature-controlled fermentation process, when the temperature inside the jar exceeds the set temperature in the fermentation room, carbon dioxide gas is injected into the jar through the middle two-way gas valve to control the temperature, so that the temperature inside the jar drops below the set temperature in the fermentation room; Step (4), performing moisture balance on the cigar tobacco leaves obtained after the fermentation in step (3).

2. The method for anaerobic fermentation of cigar tobacco leaves by using a ceramic pot according to claim 1, characterized in that: In step (3), the humidity in the fermentation room is 60%-100%.

3. The method for anaerobic fermentation of cigar tobacco leaves by using a ceramic pot according to claim 1, characterized in that: In step (3), the humidity in the fermentation room is 80±5%.

4. The method for anaerobic fermentation of cigar tobacco leaves by using a ceramic pot according to claim 1, characterized in that: The temperature-controlled fermentation in step (3) is to control the temperature in the fermentation room to 30-47° C. and ferment at this temperature.

5. The method for anaerobic fermentation of cigar tobacco leaves by using a ceramic pot according to claim 4, characterized in that: The temperature in the fermentation room is kept constant.

6. The method for anaerobic fermentation of cigar tobacco leaves by using a ceramic pot according to claim 1, characterized in that: The temperature-controlled fermentation is a three-stage temperature-variable fermentation, including a first stage fermentation of 15 days, a second stage fermentation of 15 days, and a third stage fermentation of 30 days; The temperature of the fermentation room in the first stage is 40-50℃, the temperature of the fermentation room in the second stage is 35-40℃, and the temperature of the fermentation room in the third stage is 30-40℃.

7. The method for anaerobic fermentation of cigar tobacco leaves by using a ceramic pot according to claim 6, characterized in that: In step (3), the temperature of the fermentation room in the first stage is 47°C, the temperature of the fermentation room in the second stage is 40°C, and the temperature of the fermentation room in the third stage is 35°C.

8. The method for anaerobic fermentation of cigar tobacco leaves by using a ceramic pot according to claim 7, characterized in that: When the temperature is controlled by carbon dioxide in step (3), the injection time of carbon dioxide is 15-45S.

9. The method for anaerobic fermentation of cigar tobacco leaves by using a ceramic pot according to claim 1, characterized in that: When the moisture balance is performed in step (4), the moisture content of the tobacco leaves is balanced to 18±1%.

Images