Cigar Wrapper Production Facility Integration for Higher Leaf Yield
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Solution Overview
Problem
The traditional production of cigar wrappers is inefficient, labor-intensive, and resource-intensive, with low yield rates, high facility investment, and susceptibility to climatic conditions, leading to a shortage of high-quality cigar wrapper materials and reliance on imports.
Innovation Solution
An integrated production method that integrates seedling cultivation, transplanting, drying, and fermentation processes within a 'four in one' facility system, using a nutrient solution with specific iron and boron concentrations, and controlled environmental factors to enhance yield and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional separate production facilities for seedling cultivation, drying, and fermentation are established, then the production process can be carried out independently at each stage, but the investment cost is high and the utilization rate of facility space is low
Solution Approach 1:
The patent combines seedling cultivation, drying, and fermentation processes into a single integrated facility system. The drying rack and fermentation chamber are positioned within the same facility as the seedling cultivation area, allowing multiple production stages to occur simultaneously in one space. This merging approach maintains process independence while significantly improving facility space utilization and reducing investment costs.
Solution Approach 2:
The integrated facility system serves multiple functions: it supports seedling cultivation with controlled lighting and nutrition, provides drying capacity with adjustable racks, and offers fermentation space with temperature control. This multi-functional design eliminates the need for separate specialized facilities for each production stage, reducing overall facility investment while maintaining operational independence.
2Productivity
If field planting with traditional management methods is used, then the production front is long and occupies many production facilities, but the process is greatly affected by climatic conditions and labor intensity is high
Solution Approach 1:
The patent transforms the production environment from uncontrolled field conditions to a controlled facility environment with adjustable parameters. Lighting intensity, nutrient solution composition, temperature, and humidity are all precisely controlled within the facility, eliminating susceptibility to external climatic conditions like drought, flooding, and wind disasters while maintaining high productivity.
Solution Approach 2:
The integrated facility system provides self-contained environmental control and resource management. The system includes its own lighting, nutrition delivery, irrigation, and temperature control mechanisms, eliminating dependence on external climatic conditions and reducing the need for extensive field management operations.
3Ease of manufacture
If conventional nutrient solutions are used in transplanting, then the cultivation process is simple, but the yield of cigar wrappers remains below 30%
Solution Approach 1:
The patent optimizes nutrient solution parameters, specifically increasing iron content to 0.3-0.7 mM and boron content to 9.5-13.0 mg/L. These parameter changes in the nutrient solution composition significantly improve wrapper yield to over 65% while maintaining the simplicity of the hydroponic cultivation process and automated nutrition delivery system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method achieves a yield of over 65% cigar wrappers, reduces facility investment by 40%, labor by 20%, and decreases pest and disease incidence, while improving quality and maturity.
Implementation Method 1
When transplanting tobacco seedlings, using a nutrient solution, which is a high iron boron nutrient solution with an iron content of 0.3-0.7 mM calculated as Fe and a boron content of 9.5-13.0 mg/L calculated as boric acid
Implementation Method 2
a temperature of 25±5° C. and a relative air humidity of 75%±10% within the production facility system
Implementation Method 3
a temperature of 25±5° C. and a relative air humidity of 75%±10% within the production facility system
Implementation Method 4
a photosynthetic photon flux density (PPFD) of 75-160 μmol/(m2·s)
Data Source
AI summary
The invention discloses a high-yield integrated production method for cigar wrappers. This method builds a “four in one” production facility system that integrates seedling cultivation, transplanting, drying, and fermentation processes of cigar wrapper tobacco leaves. The system has a light intensity of 75-160 μmol/(m2·s), a temperature of 25±5° C. and a relative air humidity of 75%±10%; when transplanting tobacco seedlings, using a nutrient solution, which is a high iron boron nutrient solution with an iron content of 0.3-0.7 mM calculated as Fe and a boron content of 9.5-13.0 mg/L calculated as boric acid. The invention achieves a cigar shell yield of over 65%, a 40% reduction in production facility investment, and a 20% reduction in labor force by accurately regulating the production environment and the supply of growth factors such as nutrients and light.