A condensation granulation system for functional dry beads

Abstract

This application discloses a condensation granulation system for functional dry beads, belonging to the field of functional granule manufacturing technology, and applicable to the large-scale production of functional granules for cigarette filter rods. The system includes a material pretreatment mechanism, a dripping unit, a condensation unit, and a solid-liquid separation unit. It can also be supplemented with low-temperature drying, screening, and functional substance addition units, with each unit connected to form a continuous automated production line. The system achieves uniform mixing of the substrate through a high-speed mixing tank, precise droplet preparation through the coordinated operation of a metering pump and a peristaltic pump, rapid and uniform solidification of the droplets through a concentric double-layer cylindrical tube condensation forming chamber and a closed-loop condensation medium circulation system, and solid-liquid separation through a rotary conveyor belt. Finally, it produces multifunctional cigarette dry beads with a porous structure and no packaging material, possessing both adsorption and heat release properties, reducing flavor loss and eliminating packaging material odor pollution.

Description

Technical Field

[0001] This application relates to the field of functional particle manufacturing technology, specifically to a condensation granulation system for functional dry beads. Background Technology

[0002] Traditional tobacco functional particles often require packaging materials for encapsulation and have relatively limited functions, primarily encapsulating liquid flavorings and fragrances for release during use. Cold granulation, on the other hand, can produce independent functional particles without packaging support, which can be directly added to the filter rod substrate. These particles offer a wider range of functions, including flavoring substances, and can also incorporate tar-reducing active ingredients, antioxidants, and other compounds into the particle matrix, forming structurally stable spherical particles through cold granulation technology.

[0003] To achieve the formation of wall material without chemical reaction during condensation granulation, the granular material can be adjusted and the condensation temperature parameters controlled. The granular substrate is directly dripped into the condensation medium for molding. The initial temperature of the condensation medium is controlled at a low level. After the granular substrate droplets enter, the surrounding and rapid heat exchange of the condensation medium causes the granular matrix components to cool and solidify rapidly, forming porous solid particles with a certain strength and shape. The condensed particles are drained, dried with cold air, and the moisture content is controlled. After screening and impurity removal, qualified solid particles are obtained. Subsequently, through post-fragmentation, volatile fragrances can be locked in the pores of the particles and directly added to the filter rod. These particles have sufficient adsorption capacity and heat release performance. No additional action is required during use, such as crushing or breaking them. They can selectively adsorb specific substances in the flue gas or release their components under heating conditions, which reduces the volatilization loss during fragrance processing and storage and avoids odor pollution that may be caused by packaging materials.

[0004] Drip-condensation granulation technology, through precise droplet control and rapid condensation and solidification, enables functional substrates to form stable functional structures without packaging materials. This broadens the types and applications of tobacco granules, becoming a key technological support for the tobacco industry's transformation towards high-quality development. Through intelligent equipment upgrades and material formulation optimization, its application space in diverse tobacco forms is further expanded. The key technical points of drip-condensation granulation technology can be summarized as raw materials and formulation, dripping, condensation heat transfer, equipment and systems, and post-processing and quality control. Condensation heat transfer must achieve rapid and uniform solidification to prevent structural collapse. Equipment and systems emphasize the consistency of automated control and continuous production, with the core being precise control of the heat transfer rate and optimization of the equipment structure to ensure uniform, round, and strength-compliant granules. Summary of the Invention

[0005] The purpose of this application is to provide a condensation granulation system for functional dry beads, which is a dedicated continuous granulation equipment for functional materials used in tobacco. It takes liquid condensation as its core and achieves uniform granulation, rapid solidification and clean collection of liquid materials. It is suitable for the large-scale production of functional particles for cigarette core materials and filter rods.

[0006] A condensation granulation system for functional dry beads is characterized by comprising a material pretreatment mechanism, a dripping unit, a condensation unit, and a solid-liquid separation unit, wherein each unit is connected in sequence via a conveying medium to form a continuous and automated granulation channel.

[0007] The material pretreatment mechanism includes a high-speed mixing tank 1 and a constant temperature heating jacket 2, wherein the constant temperature heating jacket 2 is wrapped around the high-speed mixing tank 1, and a storage tank 3 is connected to the rear end of the high-speed mixing tank 1; the mixing speed of the high-speed mixing tank 1 is 500-1500 r / min; the temperature control accuracy of the constant temperature heating jacket 2 is ±1℃; the function of the material pretreatment mechanism is to achieve uniform mixing of the particulate adsorption substrate and the cross-linked structure substrate, and ensure stable material flowability.

[0008] The dripping unit includes a metering pump 4, a peristaltic pump 5, an array of drippers 6, and a drip distance adjustment lifting bracket 7. The storage tank 3 and the array of drippers 6 are connected by a conduit network composed of a main pipe 8 and a branch pipe 9. The metering pump 4 and the peristaltic pump 5 are set in the middle of the two. The metering pump 4 is set on the main pipe 8 to provide a stable material to the drippers 6. The peristaltic pump 5 is set on the branch pipe 9 to provide a regular and controlled core liquid supply to the material.

[0009] The condensation unit includes a condensing medium receiving tank 10, a condensation forming chamber 11, and a micro circulation pump 12. The condensing medium receiving tank 10 is a rectangular container that holds the condensing medium. The condensation forming chamber 11 is placed inside the tank and is a concentric double-layered cylindrical tube. Both ends of the outer tube 11-1 are open, and the upper end of the inner tube 11-2 faces the dripper 6. Several connection points 11-3 are provided between the inner tube 11-2 and the outer tube 11-1. The upper end of the inner tube 11-2 is level with the liquid surface of the condensing medium, and the upper end of the outer tube 11-1 is higher than the upper end of the inner tube 11-2. The lower end of the inner tube 11-2... The end port extends beyond the lower end port of the outer tube 11-1, and a micro circulation pump 12 is installed at the lower end port of the outer tube 11-1. It is connected to an external power source through a wire closely attached to the wall of the outer tube 11-1. The micro circulation pump 12 transports the condensing medium from bottom to top and envelops the droplets falling from the dripper 6, which flow downwards along the upper end port of the inner tube 11-2. The liquid surface formed by the overflow from the outside to the inside covers the upper end port of the inner tube 11-2, preventing external gas from entering the inner tube 11-2. The droplets are cooled and shaped as they fall in the inner tube 11-2, and are guided from the lower end port of the inner tube 11-2 to the solid-liquid separation unit along with the liquid flow in the inner tube 11-2.

[0010] The condensation unit is also equipped with a cooling system for the condensing medium. The condensing medium is transported to the compression refrigeration unit 13 for heat exchange through a conduit located at the bottom of the condensing medium receiving tank 10. The temperature of the condensing medium is maintained at the condensing temperature ±1℃. Then, the cooled condensing medium is transported back to the condensing medium receiving tank 10 by a centrifugal pump for further condensation and granulation, forming a closed-loop cycle to ensure the temperature stability of the medium.

[0011] The solid-liquid separation unit includes a collection tank located outside the condensing medium receiving tank 10. One end of the collection tank is connected to the lower end of the inner tube 11-2, and the other end is connected to an upwardly inclined rotary conveyor belt 14. Flexible permeable grids 14-1 are evenly spaced on the rotary conveyor belt 14 to gradually separate the formed particles from the collection tank and send them to the low-temperature drying unit.

[0012] Preferably, it also includes a low-temperature drying unit, which uses an inclined rotating screen and a normal-temperature fan above the rotating screen to blow air onto the continuously rotating particles in the rotating screen to dry them, gradually producing dry beads.

[0013] Preferably, a temperature sensor is installed at the lower middle position of the inner tube 11-2 to detect the temperature change of the condensing medium.

[0014] Preferably, a screening unit and a functional substance addition unit are subsequently provided, including a surface spraying device or an immersion adsorption device, and a corresponding drying unit, to finally obtain functional dry beads.

[0015] The operation flow of the granulation system described in this application is as follows: In the material pretreatment stage, the particulate adsorption substrate and the cross-linked structure substrate are first put into the high-speed mixing tank 1 and mixed at a speed of 500-1500 r / min. The constant temperature heating jacket 2 around the high-speed mixing tank 1 maintains the material constant temperature with a control accuracy of ±1℃ to ensure the material flowability. The processed material is then transported to the storage tank 3 for later use.

[0016] In the granulation stage, the material in the storage tank 3 is transported to the dripper array 6 through the conduit network. The metering pump 4 on the main pipe 8 provides a stable material supply to the dripper 6, while the peristaltic pump 5 on the branch pipe 9 precisely controls the core liquid supply according to the pattern. At the same time, the height of the dripper 6 is adjusted by the lifting bracket 7 so that the material forms uniform droplets and drips to the condensation unit below.

[0017] During the condensation and molding stage, droplets fall vertically into the inner tube 11-2 of the condensation and molding chamber 11. The condensation medium in the condensation medium receiving tank 10 is driven by the micro circulation pump 12 and transported upward from the bottom of the inner and outer spaces of the double-layer cylindrical tube, forming an overflow liquid surface from the outside to the inside and covering the inner tube 11-2 opening to isolate external gas. During the droplet's fall in the inner tube 11-2, it is rapidly enveloped and heat-exchanged by the condensation medium, achieving rapid cooling and solidification. The temperature sensor at the lower part of the inner tube 11-2 monitors the medium temperature in real time. When the temperature deviates from the set value, the condensation medium is transported to the compression refrigeration unit 13 through the bottom conduit for heat exchange and cooling, and then returned to the condensation medium receiving tank 10 by the centrifugal pump, forming a closed loop circulation to ensure that the condensation medium temperature is stable at the condensation temperature ±1℃. The molded particles are guided by the liquid flow to the solid-liquid separation unit at the bottom of the condensation medium receiving tank 10.

[0018] In the solid-liquid separation stage, the condensed and formed particles enter the rotary conveyor belt 14 of the solid-liquid separation unit. The flexible permeable grid 14-1 on the conveyor belt can initially separate the liquid on the particles. At the same time, the conveyor belt transports the separated particles to the low-temperature drying unit.

[0019] During the low-temperature drying stage, the particles enter the inclined rotating screen of the low-temperature drying unit. A normal-temperature fan above the screen blows air continuously, and the particles are dried evenly as the screen rotates, accurately controlling the moisture content of the particles and ensuring the stability of the particle structure and function.

[0020] In the subsequent processing stage, the dried granules first enter the screening unit for impurity removal and screening to obtain qualified granules with the required particle size and morphology. Then, they enter the functional substance addition unit, where functional substances such as flavorings and tar-reducing components are added through surface spraying or internal adsorption. Finally, they undergo secondary drying in the matching drying unit to form functional dry bead granules for tobacco with specific functions. Beneficial effects

[0021] The functional dry bead condensation granulation system proposed in this application is a dedicated continuous granulation equipment for tobacco functional materials. Compared with traditional tobacco functional granule preparation technology, it has multiple technical advantages and application value. It realizes the preparation of independent functional granules without packaging material support, avoiding the odor pollution caused by traditional packaging materials. At the same time, the granules can integrate multiple functional components such as flavor substances, tar-reducing active ingredients, and antioxidants, forming structurally stable porous spherical granules. These granules have both the function of adsorbing specific substances in smoke and the function of heat release. No additional action such as crushing is required during use. It is feature-rich and highly practical.

[0022] The condensation granulation process enables the particle matrix to form a porous structure with excellent adsorption capacity and heat release performance. Subsequent flavoring processes can lock volatile fragrances within the particle pores, significantly reducing volatilization losses during fragrance processing and storage, ensuring fragrance utilization and particle aroma release stability. The dripping unit employs a dual-pump collaborative feeding mode of metering pump 4 and peristaltic pump 5. Metering pump 4 provides a stable supply of material to the main pipe 8, while peristaltic pump 5 precisely controls the core liquid supply to the branch pipe 9. Combined with the drip distance adjustment mechanism, uniform droplet formation is achieved, ensuring consistent particle size. The condensation unit uses a concentric double-layer cylindrical tube condensation forming chamber 11 structure, combined with the cooling capacity of the compression refrigeration unit 13. The closed-loop circulation system for the condensing medium can maintain the temperature of the condensing medium within ±1℃ of the condensing temperature, enabling rapid and uniform solidification of droplets, preventing particle structure collapse, and ensuring particle roundness and strength. At the same time, the liquid surface formed by the overflow from the outer tube 11-1 can isolate external gases and ensure uniform heat dissipation in the condensing environment. The rotary conveyor belt 14 of the solid-liquid separation unit, combined with the flexible permeable grid 14-1 structure, can achieve efficient and clean separation of the formed particles and the condensing medium, avoiding secondary contamination of the particles. The low-temperature drying unit adopts a drying method of rotary screen + normal temperature fan, which can ensure that the moisture content of the particles meets the standard while avoiding damage to the functional components of the particles by high temperature. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the granulation system described in this application.

[0024] Figure 2 yes Figure 1 A magnified view of a portion of the image.

[0025] Figure 3 yes Figure 1 A magnified view of a portion of the image, B.

[0026] Figure 4 This is a schematic diagram of the structure of the condensation molding chamber.

[0027] Figure 5 This is a bottom view of the condensation molding chamber.

[0028] In the diagram, the components are: 1. High-speed mixing tank; 2. Constant temperature heating jacket; 3. Storage tank; 4. Metering pump; 5. Peristaltic pump; 6. Dripping head; 7. Lifting support; 8. Main pipe; 9. Branch pipe; 10. Condensate container; 11. Condensation forming chamber; 11. Outer pipe; 11-1. Inner pipe; 11-2. Connection point; 11-3. Micro circulation pump; 12. Compression refrigeration unit; 13. Rotary conveyor belt; 14. Flexible permeable grid; 14-1. Detailed Implementation

[0029] The functional dry bead condensation granulation system of this application will be described in detail below with reference to the accompanying drawings and specific embodiments. This embodiment is only used to illustrate the technical solution of this application and does not constitute a limitation on the scope of protection of this application. Example 1

[0030] refer to Figure 1-5 This embodiment provides a condensation granulation system for preparing tar-reducing functional dry beads for tobacco. The system includes a material pretreatment mechanism, a dripping unit, a condensation unit, a solid-liquid separation unit, a low-temperature drying unit, a screening unit, and a functional substance addition unit. Each unit is sequentially connected to a transmission component via a food-grade low-temperature resistant conveying pipeline to form a continuous and automated production line for functional tobacco granules.

[0031] Its operation process is as follows: ① Material pretreatment: In this embodiment, a specific ratio of porous starch and diatomaceous earth is added into a high-speed mixing tank 1, an appropriate amount of deionized water is added, the stirring device is started and the speed is adjusted to 800 r / min, and the constant temperature heating jacket 2 around the tank is turned on to precisely control the temperature of the material inside the tank at 45℃±1℃. The stirring is continued for 40 minutes to ensure that the porous starch and diatomaceous earth are fully mixed, ensuring that the material has stable flow properties to meet the subsequent dripping requirements. After mixing, the material is transported to the storage tank 3 for temporary storage. The storage tank is kept at a constant temperature of 40℃ throughout the process to prevent abnormal fluctuations in the viscosity of the material.

[0032] ② The mixture is granulated by dripping. The metering pump 4 on the main pipe 8 is turned on to deliver the mixed substrate in the storage tank 3 to the dripper array 6 at a stable flow rate. At the same time, the peristaltic pump 5 on the branch pipe 9 is started to supply material to the dripper at a stable flow rate. The height of the dripper 6 is adjusted to a suitable position by the drip distance adjustment lifting bracket 7 so that the mixed substrate forms droplets with uniform particle size under the action of gravity. The droplets are then regularly dripped from the dripper array to the condensation unit below.

[0033] ③ Condensation molding: In this embodiment, a mixture of food-grade anhydrous ethanol and deionized water is used as the condensing medium. The condensing medium is first cooled by a compression refrigeration unit 13 and then transported to the condensing medium receiving tank 10. The micro circulation pump 12 is started to drive the condensing medium to be transported upward from the bottom of the inner and outer layers of the double-layer cylindrical tube in the condensation molding chamber 11. An overflow liquid surface is formed from the outside to the inside at the upper end of the inner tube 11-2, completely covering the inner tube opening to isolate it from the outside air and prevent the droplet solidification process from being disturbed by the air. After the droplets fall vertically into the inner tube 11-2, they are quickly wrapped by the condensing medium and fall along the inside of the tube, completing rapid cooling and solidification in a low-temperature environment to form porous spherical particles. The temperature sensor at the lower part of the inner tube 11-2 monitors the medium temperature in real time. When the temperature rise exceeds the molding requirements, the refrigeration unit automatically starts enhanced heat exchange to restore the medium temperature to the set range, ensuring stable condensation effect. The molded particles are guided from the lower end of the inner tube to the solid-liquid separation unit along with the condensing medium liquid flow.

[0034] ④ Solid-liquid separation: After the shaped particles enter the rotary conveyor belt 14 of the solid-liquid separation unit, the condensing medium attached to the surface of the particles is filtered out in the flexible permeable grid 14-1 on the conveyor belt. The conveyor belt is inclined upward to transport the initially drained particles to the low-temperature drying unit. The separated condensing medium is returned to the condensing medium receiving tank 10 for recycling.

[0035] ⑤ Low-temperature drying: After the particles enter the inclined rotating screen, the screen rotates slowly, and at the same time, the normal temperature fan above the screen is turned on to dry the particles evenly and continuously. This process ensures that the moisture content of the particles is precisely controlled within the standard range, thus guaranteeing the stability of the particle structure.

[0036] ⑥ Subsequent processing: After drying, the granules first enter the screening unit to screen out qualified granules; then the qualified granules are sent to the functional substance addition unit, where the peppermint flavoring solution is evenly impregnated into the pores of the granules using an impregnation and adsorption device. After impregnation, they are sent to the matching drying unit for secondary air drying to remove excess solvent, and finally functional dry beads for tobacco with cooling and aroma release function are obtained. Example 2

[0037] This embodiment is used to prepare antioxidant functional dry beads for tobacco. The structure of its granulation system is the same as that in Example 1, with only the following process parameters adjusted: ① Replace the particulate substrate with microcrystalline cellulose and chitosan; ② Adjust the corresponding parameters during stages such as droplet granulation, condensation molding, and low-temperature drying; ③ The fragrance is evenly sprayed onto the surface of the granules using a surface spraying device, and then dried twice to complete the preparation of the finished product.

Claims

1. A functional dry granulation system, characterized by, It includes a material pretreatment mechanism, a dripping unit, and a condensation unit. Each unit is connected in sequence through a conveying medium to form a continuous and automated granulation channel. The material pretreatment mechanism includes a high-speed mixing tank (1) and a constant temperature heating jacket (2), wherein the constant temperature heating jacket (2) is wrapped around the high-speed mixing tank (1), and a storage tank (3) is connected to the rear end of the high-speed mixing tank (1). The dripping unit includes a metering pump (4), a peristaltic pump (5), an array of drippers (6), and a drip distance adjustment lifting bracket (7); the storage tank (3) and the array of drippers (6) are connected by a conduit network composed of a main pipe (8) and a branch pipe (9), with the metering pump (4) and the peristaltic pump (5) set in between them. The metering pump (4) is set on the main pipe (8) to provide stable material to the drippers (6); the peristaltic pump (5) is set on the branch pipe (9) to provide core liquid to the material in a regular and controlled manner. The condensation unit includes a condensation medium receiving tank (10), a condensation forming chamber (11), and a micro circulation pump (12); the condensation medium receiving tank (10) is a rectangular container that holds the condensation medium; the condensation forming chamber (11) is placed inside it and is a concentric double-layer cylindrical tube, with both ends of the outer tube (11-1) open and the upper end of the inner tube (11-2) facing the dripper (6); the inner tube (11-2) and the outer tube (11-1) are connected. Several connection points (11-3) are provided between them. The upper end of the inner tube (11-2) is level with the liquid surface of the condensing medium. The upper end of the outer tube (11-1) is higher than the upper end of the inner tube (11-2). The lower end of the inner tube (11-2) extends beyond the lower end of the outer tube (11-1). A micro circulation pump (12) is provided at the lower end of the outer tube (11-1) and is connected to an external power source through a wire that is close to the wall of the outer tube (11-1).

2. The condensation granulation system for functional dry beads according to claim 1, characterized in that, It also includes a cooling system for the condensing medium, which is connected to a compression refrigeration unit (13) through a conduit set at the bottom of the condensing medium receiving tank (10) to exchange heat with the condensing medium, and then the cooled condensing medium is transported to the condensing medium receiving tank (10) by a centrifugal pump.

3. The condensation granulation system for functional dry beads according to claim 1 or 2, characterized in that, It also includes a solid-liquid separation unit, which includes a collection tank located outside the condensing medium receiving tank (10). One end of the collection tank is connected to the lower end of the inner tube (11-2), and the other end is connected to the inclined upward rotary conveyor belt (14). Flexible permeable grids (14-1) are evenly spaced on the rotary conveyor belt (14) to separate the formed particles from the collection tank.

4. The condensation granulation system for functional dry beads according to claim 1 or 2, characterized in that, It also includes a low-temperature drying unit, which uses an inclined rotating screen with a normal-temperature fan above it to blow air and dry the particles that are constantly rotating in the screen.

5. The condensation granulation system for functional dry beads according to claim 3, characterized in that, It also includes a low-temperature drying unit, which uses an inclined rotating screen with a normal-temperature fan above it to blow air and dry the particles that are constantly rotating in the screen.

6. The condensation granulation system for functional dry beads according to claim 1, characterized in that, A temperature sensor is installed at the lower middle position of the inner tube (11-2) to detect the temperature change of the condensing medium.

7. The condensation granulation system for functional dry beads according to claim 4, characterized in that, It also includes a screening unit and a functional substance addition unit.

8. The condensation granulation system for functional dry beads according to claim 7, characterized in that, The functional substance addition unit includes a surface spraying device or an immersion adsorption device, and a corresponding drying unit.

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