Tobacco Leaf Drying Method for Enzymatic Browning Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Tobacco materials dried using existing methods lose their green color during processing, resulting in dark-colored extracts when used in oral tobacco products, which is undesirable for user experience.
Innovation Solution
A method involving heating tobacco leaves at 75°C or higher in a humidity-controlled environment with relative humidity between 3% RH and 60% RH to inactivate polyphenol oxidase enzymes, maintaining the green color and preventing enzymatic browning, thereby ensuring a light-colored extract.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If tobacco leaves are dried using conventional drying methods, then the drying process is completed, but the green color is lost and enzymatic browning occurs resulting in dark-colored extracts
Solution Approach 1:
The invention changes the drying parameters by controlling both temperature (60-80°C) and relative humidity (70-90%) simultaneously, and by introducing a post-drying cooling step to inactivate enzymes. This parameter control prevents enzymatic browning while maintaining green color, resolving the contradiction between completing drying and preventing harmful browning effects.
Solution Approach 2:
The invention performs preliminary cooling after drying to inactivate polyphenol oxidase enzymes before they can cause browning. This preliminary action of cooling and enzyme inactivation prevents the harmful browning effect from occurring, allowing the tobacco material to maintain its green color while being fully dried.
2Ease of manufacture
If tobacco leaves are dried to maintain green color, then the green color is preserved, but the extract becomes dark-colored due to enzymatic browning
Solution Approach 1:
The invention controls drying parameters (temperature 60-80°C, humidity 70-90%) to preserve green color during drying, then applies a post-drying cooling step to inactivate enzymes. This two-stage parameter control ensures both green color retention and prevention of enzymatic browning, eliminating the harmful dark-colored extract effect.
Solution Approach 2:
The invention converts the potential harmful effect of enzymatic browning into a beneficial outcome by using the controlled drying process to concentrate the tobacco material while maintaining green color, followed by cooling to inactivate enzymes. The drying process itself becomes beneficial when properly controlled, preventing rather than causing browning.
3Productivity
If conventional drying methods are used, then drying efficiency is achieved, but the tobacco material undergoes yellowing and color loss
Solution Approach 1:
The invention optimizes drying parameters by controlling temperature (60-80°C) and relative humidity (70-90%) within specific ranges, and by adding a post-drying cooling step. This controlled parameter approach maintains green color appearance while achieving efficient drying, resolving the contradiction between drying productivity and color preservation.
Solution Approach 2:
The invention performs preliminary cooling after the drying process to inactivate enzymes before they can cause yellowing or color loss. This preliminary protective action ensures that the tobacco material maintains its green color appearance while still achieving efficient drying throughput.
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 effectively retains the green color of tobacco materials and results in a light-colored extract when used in oral tobacco products, enhancing user experience by preventing dark coloration in the oral cavity.
Implementation Method 1
heating tobacco leaves at 75°C or higher in a humidity-controlled environment to inactivate polyphenol oxidase enzymes
Implementation Method 2
heating tobacco leaves at 75°C or higher in a humidity-controlled environment with relative humidity between 3% RH and 60% RH
Data Source
Figure 1(a)~1(b)
Figure 2(a)~2(b)
Figure 3(a)~3(b)
AI summary
Provided is a method of manufacturing a tobacco raw material in which the green color of the tobacco raw material is maintained and a browning-involved enzyme included in tobacco leaves is deactivated. Specifically, a method of manufacturing a tobacco raw material is provided that includes a step for heating a tobacco leaf material, which has an a* value of 1.0 or less, the a* value being expressed by the L*a*b* method, and which has a moisture content of 8 wt% or less, at a temperature of 75°C or higher and under a humidity-controlled environment so that the a* value is 1.0 or less and the content of the browning-involved enzyme is 0.1 U/g or less.