CN111728258A - Pretreatment process for shredding tobacco flakes - Google Patents

Abstract

The invention provides a tobacco flake shredding pretreatment process, which determines core parameters of working condition environment temperature and humidity control through tobacco flake equilibrium moisture content test data of a laboratory and month meteorological data with optimal process quality indexes and dust removal amounts; the technological process before shredding the tobacco sheets is improved, so that the temperature and the moisture of the tobacco sheets before shredding reach the optimal working condition; carrying out full-formula working condition parameter test and optimization and establishing a process standard; after the method is implemented, the total amount of broken pieces and dust generated in the shredding process can be reduced.

Description

Pretreatment process for shredding tobacco flakes

Technical Field

The invention relates to the field of cigarette production and processing, in particular to a tobacco slice shredding pretreatment process.

Background

At present, the tobacco slice warming method and equipment before shredding in the tobacco shred making production line of domestic cigarette enterprises are all according to the technology and equipment of cigarette process specification (ISBN 978-7-5019-8637-8)/sixth cut tobacco/6.1 tobacco slice warming compiled by the national tobacco monopoly. The main characteristics are as follows: the temperature of the tobacco flakes is properly increased by using a 'leaf heating cylinder' device, the temperature of the tobacco flakes is required to be 30.0-40.0 ℃, meanwhile, the tobacco flakes are loosened and unfolded, and the processing resistance of the tobacco flakes is improved.

In practice, the technical scheme required by the cigarette technical specification has poor application effect. The existing process design defect is that the tobacco flake is an agricultural and sideline product, and needs to be further processed and cut into 0.6-1.0 mm tobacco shreds, the processing resistance is closely related to the moisture content of the tobacco flake besides the temperature, and the related moisture content index parameters of the tobacco flake before shredding, the tobacco flake conveying process and the temperature and humidity parameters of the 'leaf temperature increasing' process in the cigarette process specification are blank.

Furthermore, the equipment application defect based on the existing process requirements is that the blade temperature-increasing cylinder can only provide the temperature-increasing function of unidirectional control of the application steam, the humidifying effect of the steam temperature increase is related to the incoming material of the previous process and the working condition temperature and humidity of the workshop environment, obvious uncontrollable performance exists, and the process parameters are difficult to calibrate; when the temperature is higher in summer, the tobacco flakes do not need to be heated, and the tobacco flakes enter a blade heating cylinder, and the additional crushing is added; when the temperature was lower winter, the smoked sheet was followed "blade section of thick bamboo that heats and is gone out a section of thick bamboo after, and there is great difference in temperature wet difference in transportation process and environment, and contact with outside dry and cold air longer time, if: the turnover of the feeder is kept for 10-15 minutes, but the moisture of the tobacco flakes on the surface layer is rapidly dissipated, and the processing resistance of the tobacco flakes is rapidly reduced rather than being better.

According to the regulations of the national tobacco monopoly and the tobacco industry standard, the cigarette grades are divided into five different categories. In the common cognition of consumers, the three grades of the Chinese traditional medicine are divided into a high grade, a middle grade and a low grade. The high-grade, medium-grade and low-grade main formula tobacco flakes have different moisture absorption characteristics due to different growing positions on tobacco plants, and have obvious differences in crushing resistance and processing resistance in the shredding process. Therefore, in the production process of cigarette enterprises, the processing technological parameters including the process need to be further designed and refined according to the physical properties of the tobacco flakes used by different types and grades of cigarette products.

Based on the defects of the process design and the application practice and the physical characteristics of the tobacco flake raw materials, the technical personnel in the field need to find a method which can meet the shredding process requirements of tobacco flakes in formulas of various types and grades and can stably ensure the shredding process quality under the working conditions of temperature and humidity of different workshop environments.

Disclosure of Invention

The invention aims to provide a pretreatment process for shredding tobacco sheets, which is used for solving the problems in the prior art. In order to achieve the above objects and other related objects, the technical solution of the present invention comprises the steps of:

1) the equilibrium moisture content parameter fitting optimization test before shredding tobacco sheets in a laboratory: selecting single-grade tobacco sheets of formula main materials respectively representing high-grade, medium-grade and low-grade cigarette brands, fitting the standard requirements of the production process, loosely humidifying to reach the moisture content of 18-21%, respectively placing the tobacco sheets in temperature and humidity adjusting test boxes of temperature and humidity parameters designed according to process design and combined gradient tests, balancing for 4 hours, and then detecting the balanced moisture content of the tobacco sheets of formula main materials in the process section and under different temperature and humidity working conditions according to a method of YC/T31-1996 preparation and moisture measurement oven method for tobacco and tobacco product samples.

Further, according to the temperature and humidity parameters of the process design and the combined gradient test design, the equilibrium temperature and humidity range of the moisture content of the tobacco flakes of the process design is as follows: the temperature is 24-36 ℃, and the relative humidity is 60-80%; the equilibrium temperature and humidity gradient step value of the water content of the tobacco flakes designed by the combined gradient test is as follows: the temperature is +/-2 ℃, and the relative humidity is +/-5%.

2) The fitting of the environmental working condition humiture and the tobacco flake equilibrium water content parameter is preferred: the method is characterized in that the method takes annual output of more than 10 hundred million cigarettes and four-season balanced production all the year round as screening conditions, high-grade, medium-grade and low-grade brand cigarettes are screened, the shredding temperature and the moisture content of each batch of tobacco shreds at 1-12 months in a complete production year and the distribution state of shredding rate indexes of semi-finished tobacco shreds are statistically analyzed, and the month with the optimal screening process quality index is selected.

Further, in the same way, the month with the lowest dust removal amount of the unit product is screened.

Furthermore, historical meteorological data are inquired from the month with the optimal shred breaking rate process quality index and the minimum dust removal amount per unit yield, and the temperature and humidity distribution range of the working condition of the workshop environment is determined.

Further, combining the step 1, preliminarily determining core design parameters of the shredding temperature and the moisture content of the high-grade, medium-grade and low-grade cigarettes, and determining core parameters of the working condition environment temperature and humidity control of the pre-shredding treatment.

3) The technological process before shredding the tobacco sheets is improved: redesigning the production process flow before shredding the tobacco sheets according to the shredding temperature, the moisture content and the core parameters of the working condition environment temperature and humidity control determined in the step 1 and the step 2, wherein the production process flow comprises the following characteristics:

a. the technological process improvement of the tobacco flake shredding pretreatment: the method comprises the steps of removing the working procedures of ' temperature rise of leaves ' from the original process flow of ' cabinet removal of leaves, transportation of leaves ', temperature rise of leaves, quantitative feeding and shredding ', and reserving the working procedures of ' cabinet removal of leaves, transportation of leaves, quantitative feeding and shredding '.

b. The heat and moisture exchange characteristic of the tobacco flake before shredding is improved: the method is characterized in that natural heat and moisture exchange between materials and a production environment is improved into a process flow of 'leaf cabinet removal, leaf conveying, quantitative feeding and shredding', and local environment temperature and humidity control is implemented, and the specific method comprises the following steps:

and (2) sending the air which is determined according to the step (1) and the step (2) and controls the working condition environment temperature and humidity parameters to a 'leaf cabinet-leaving-leaf conveying-quantitative feeding-shredding' process flow line through a main air supply pipe by an air conditioning unit, further forming a local temperature and humidity control area through laser punching of a tail end air pipe distributed above or laterally above the process flow line, and carrying out process treatment on the conveyed tobacco flakes needing shredding.

c. The functional characteristics of the pretreatment process for shredding tobacco sheets are as follows: through the process flow treatment, the temperature is higher than or lower than the design value, the water content is higher than or lower than the design value, or the former process incoming materials in different combination forms among the temperature and the water content can be rectified to be within the process design and control range, and the shredding under the optimal working condition all the year around is realized.

4) The working condition parameter test and optimization of the product full formula smoked sheet are as follows: and (3) according to laboratory test data of the single-grade smoked sheets in the step (1), working condition tests are carried out by combining the grades of the fully formulated smoked sheets of the product, the optimal process quality and the process parameter with the lowest dust breakage consumption are comprehensively screened, and the process standards of high-grade, medium-grade and low-grade brands are established.

After adopting the technical scheme, compared with the prior art, the invention has the following beneficial effects: determining core parameters of the temperature and humidity control of the working condition environment through the balance moisture content test data of the tobacco flakes in a laboratory and the month meteorological data with optimal process quality indexes and dust removal amounts; the technological process before shredding the tobacco sheets is improved, so that the temperature and the moisture of the tobacco sheets before shredding reach the optimal working condition; carrying out full-formula working condition parameter test and optimization and establishing a process standard; after the method is implemented, the total amount of broken pieces and dust generated in the shredding process can be reduced.

Drawings

FIG. 1: graph of the equilibrium moisture content of tobacco flakes with different grades according to the relative humidity (temperature 30 ℃ C. state)

FIG. 2: graph of the equilibrium moisture content of tobacco flakes with different grades according to the temperature (at 70% relative humidity)

Detailed Description

The embodiments of the present invention are described below with specific examples, and other advantages and effects of the present invention will be easily understood by those skilled in the art from the disclosure of the present specification. The invention is capable of other and different embodiments and of being practiced or of being carried out in various ways, and its several details are capable of modification in various respects, all without departing from the spirit and scope of the present invention.

Example (b):

the technical process layout of a certain cigarette factory N in the urban area in south China is similar to the requirement of cigarette technical specification compiled by the national tobacco monopoly, in the actual production process, the tobacco flake has low processing resistance and large breakage in the process, the average single box (5 ten thousand) dust amount in 2017 plus materials in 2018 is 2.53kg, and the dust breakage loss ratio reaches 7.7 percent of the total feeding amount (according to 33.0 kg/box). Calculated according to the N-year yield of a cigarette factory of 75 ten thousand boxes, the total amount of tobacco dust reaches 1895 tons every year, partial dust peculiar smell overflows to cause complaints of surrounding residents, and great environmental protection pressure exists.

The technical scheme adopted by the invention

Step 1

According to the use condition of the main material smoked sheets in the formula, 2kg of single-grade smoked sheets of C2F, B3F and X3L in a Yunnan Trijing smoked sheet production area are selected respectively, are loosened and humidified to reach the moisture content of 18-21%, and are then placed in a laboratory temperature and humidity regulating test box.

The temperature of the temperature-adjusting humidity-adjusting test box is set to be 24 ℃ and the relative humidity is set to be 60% for the first time, and after balancing for 4 hours, the balanced moisture content of the main material tobacco flakes of the three formulas is detected according to a method of YC/T31-1996 oven method for preparing samples of tobacco and tobacco products and measuring moisture.

Further, the above experiment was repeated with the adjustment of the step value parameter. The equilibrium temperature and humidity range of the water content of the tobacco flakes is designed according to the procedures: the temperature is 24-36 ℃, and the relative humidity is 60-80%; the equilibrium temperature and humidity gradient step value of the water content of the tobacco flakes designed by the combined gradient test is as follows: the temperature is +/-2 ℃, and the relative humidity is +/-5%.

And (5) testing results. Intermediate values of the selected test parameter ranges: the test results at 30 deg.C/70% are shown in FIGS. 1-2

FIG. 1: graph of the equilibrium moisture content of tobacco flakes with different grades according to the relative humidity (temperature 30 ℃ C. state)

FIG. 2: graph of the equilibrium moisture content of tobacco flakes with different grades according to the temperature (at 70% relative humidity)

And (4) analyzing the data and concluding:

under different temperature and humidity gradient setting conditions, the equilibrium moisture content of Yunnan Trijing single-grade C2F, B3F and X3L smoked sheets is greatly influenced by humidity and is not obviously influenced by temperature, and the moisture control of the smoked sheets is mainly realized by controlling the relative humidity.

Step 2

And carrying out statistical analysis on monthly production process data in 2017 and 2018, and finding that the month with the lowest dust removal amount of a single box is 3-5 months and the next lowest month is 10-11 months. 2017-2018, wherein the average single-box dust removal amount in 3-5 months is 2.10 kg/box, and the average single-box dust removal amount in 9-10 months is 2.25 kg/box.

The data of the fluctuation of the broken filament rate indexes of more than 10 hundred million different grades produced in different months are statistically analyzed, and the positive correlation between the single-box dust removal amount and the fluctuation of the broken filament rate indexes is found. The average shredding rate of 2017-2018 is 1.40%, wherein the average shredding rate of 3-5 months tobacco sheets after shredding is 1.12%, and the average shredding rate of 10-11 months is 1.20%.

According to the regional climate characteristics of the cigarette factory N, the spring and summer are crossed in 3-5 months, and the autumn and winter are crossed in 10-11 months. The historical data of the environmental temperature and humidity inside and outside the factory are analyzed, and the typical environmental temperature range in the period is 24-32 ℃, the fluctuation range of the relative humidity is large, the relative humidity in the 3-5 month 'return-to-south' period is more than 90%, the period of 10-11 months is dry, and the minimum relative humidity is less than 30%.

And (4) analyzing the data and concluding:

under the working condition of the prior art, the processing resistance (shredding rate and single-box dedusting amount) of the tobacco flakes is greatly influenced by the ambient temperature and is not obviously influenced by the relative humidity of the environment. Therefore, the temperature of the tobacco flakes should be controlled within 24-32 ℃ during the processing.

Further, combining step 1 and step 2, the optimal design parameter range of the fitting of the environmental working condition humiture and the equilibrium moisture content parameter of the tobacco flakes is as follows: the water content of the tobacco flakes of the corresponding processing brand is 18-21%, the design temperature of the environment is controlled to be 24-32 ℃, and the relative humidity is 72-80%.

Step 3

And (3) according to the environment temperature and humidity design and control range determined in the step (1) and the step (2) and the improvement requirement on the layout of the cigarette process flow, recombining and improving the processing flow of the original process by the cigarette factory N. Mainly comprises the following steps: A. in the original process flow of 'leaves out of cabinet, leaves conveying, leaves warming, quantitative feeding and shredding', the 'leaves warming' process equipment is dismantled and connected by a conventional vibration conveying trough; B. a set of 10000 cubic/hour small air conditioning unit is newly added, air conditioning air with the temperature of 24-32 ℃ and the relative humidity of 72-80% can be sent to a 'leaf cabinet-taking-out-leaf conveying-quantitative feeding-shredding' process flow line through a main air supply pipe, and further a local temperature and humidity control area is formed through laser punching of a tail end air pipe distributed above or laterally above the process flow line, and tobacco sheets before shredding are subjected to process treatment.

Step 4

Through the steps 1-3, each grade product has the conditions of on-line working condition test and technological parameter optimization of the full-formula smoked sheet. Taking a full-formula tobacco flake grade process orthogonal test of a high-grade brand A as an example, combining the requirements of processing process parameters of front and back procedures, selecting different temperatures, relative humidities and water contents, and statistically analyzing the index of the shred breaking rate in the tobacco shred processing process, preferably selecting scientific and reasonable industrial control parameters of environment temperature and humidity and tobacco flake water content.

Factor level meter

Influence of tobacco shred processing quality under different test conditions

Through the above L₉(4³) Orthogonal experiments can lead to that: under the conditions that the temperature of the high-grade brand A is 2 level, the relative temperature is 3 level and the water content is 1 level, namely the temperature is 28 ℃, the relative humidity is 73 percent and the water content is 18.7 percent, the shredded rate index of the shredded tobacco sheets is 0.87 percent at the lowest. Namely, the optimal shredding working condition is as follows: the temperature was 28 ℃, the relative humidity was 73%, and the water content was 18.7%.

Repeating the steps, preferably obtaining the process core control parameters of other grades of brands, and further establishing the process technical standards of high, medium and low grades of brands under the new process flow conditions.

Effects of the implementation

Through the technical improvement, standard new construction and popularization and application, the processing resistance of the tobacco flakes of each grade brand produced by the cigarette factory N is obviously improved, and dust breakage in the manufacturing process is obviously reduced. According to the single-box dust removal amount counted by the N power plants of the cigarette factory, the average value before the implementation in 2017 and 2018 is 2.53 kg/box; the pressure is reduced to 2.10 Kg/box in the implementation process of gradually getting on-line in 5 months in 2019; after the standard is newly built and integrally implemented and verified by effect tracking, the annual average value of 2019 is further reduced to 1.90 kg/box.

According to the caliber calculation of the N-year yield of a cigarette factory of 75 ten thousand boxes, the feeding of a single box of tobacco flakes of 33 Kg/box and the price of the tobacco flakes of 100 Yuan/Kg, the loss proportion of dust crushing is reduced from 7.7 percent to 5.75 percent, and the cost is saved by more than 4000 Yuan/year; the total amount of tobacco dust is reduced from 1895 tons to 1425 tons, 470 tons and the reduction amplitude is 24.8 percent each year. The peculiar smell of the tobacco dust is obviously reduced, and the social and economic benefits are obvious.

The foregoing embodiments are merely illustrative of the principles and utilities of the present invention and are not to be construed as limiting the invention. Any person skilled in the art can modify or change the above-mentioned embodiments without departing from the spirit and scope of the present invention. Accordingly, it is intended that all equivalent modifications or changes be made by those skilled in the art without departing from the spirit and technical spirit of the present invention, and the scope of the present invention is defined by the appended claims.

Claims (1)

1. A pretreatment process for shredding tobacco sheets is characterized by comprising the following steps:

1) the equilibrium moisture content parameter fitting optimization test before shredding tobacco sheets in a laboratory: selecting single-grade tobacco sheets of formula main materials respectively representing high-grade, medium-grade and low-grade cigarette brands, fitting the standard requirements of the production process, loosely humidifying the tobacco sheets to reach the moisture content of 18-21%, respectively placing the tobacco sheets in temperature and humidity adjusting test boxes of temperature and humidity parameters designed according to process design and combined gradient test, balancing the tobacco sheets for 4 hours, and then detecting the balanced moisture content of the tobacco sheets of formula main materials in the process section and under different temperature and humidity working condition environments according to a method of YC/T31-1996 preparation and moisture measurement oven method of tobacco and tobacco product samples;

according to the temperature and humidity parameters of the process design and the combined gradient test design, the equilibrium temperature and humidity range of the moisture content of the tobacco flakes of the process design is as follows: the temperature is 24-36 ℃, and the relative humidity is 60-80%; the equilibrium temperature and humidity gradient step value of the water content of the tobacco flakes designed by the combined gradient test is as follows: the temperature is +/-2 ℃, and the relative humidity is +/-5%;

2) the fitting of the environmental working condition humiture and the tobacco flake equilibrium water content parameter is preferred: screening high-grade, medium-grade and low-grade brand cigarettes by taking annual output of more than 10 hundred million cigarettes and four-season balanced production all the year round as screening conditions, and statistically analyzing the distribution state of the shredding temperature, the moisture content and the shredding rate indexes of tobacco shred semi-finished products in each batch of tobacco shreds at 1-12 months in a complete production year and screening a month with the optimal process quality index;

further, in the same way, the month with the lowest dust removal amount of the unit product is screened;

furthermore, historical meteorological data are inquired from the month with the optimal shred breaking rate process quality index and the minimum dust removal amount per unit yield, and the temperature and humidity distribution range of the working condition of the workshop environment is determined;

further, combining the step 1, preliminarily determining core design parameters of the shredding temperature and the moisture content of the high-grade, medium-grade and low-grade cigarettes, and determining core parameters of the working condition environment temperature and humidity control of the pre-shredding treatment;

3) the technological process before shredding the tobacco sheets is improved: redesigning the production process flow before shredding the tobacco sheets according to the shredding temperature, the moisture content and the core parameters of the working condition environment temperature and humidity control determined in the step 1 and the step 2, wherein the production process flow comprises the following characteristics:

a. the technological process improvement of the tobacco flake shredding pretreatment: removing the working procedures of 'temperature increase of leaves' from the original process flow 'leaves out of a cabinet, leaves conveying, leaves temperature increasing, quantitative feeding and shredding', and reserving the working procedures of 'leaves out of a cabinet, leaves conveying, quantitative feeding and shredding';

b. the heat and moisture exchange characteristic of the tobacco flake before shredding is improved: the method is characterized in that natural heat and moisture exchange between materials and a production environment is improved into a process flow of 'leaf cabinet removal, leaf conveying, quantitative feeding and shredding', and local environment temperature and humidity control is implemented, and the specific method comprises the following steps:

air of the environmental temperature and humidity parameters of the working condition determined in the step 1 and the step 2 is sent to a 'leaf cabinet-outlet-leaf conveying-quantitative feeding-shredding' process flow line through a main air supply pipe by an air conditioning unit, and a local temperature and humidity control area is formed by laser punching of a tail end air pipe distributed above or laterally above the process flow line, and the conveyed tobacco sheets needing shredding are subjected to process treatment;

c. the functional characteristics of the pretreatment process for shredding tobacco sheets are as follows: through the processing of the process flow, the incoming materials of the former process with the temperature higher than or lower than the design value and the water higher than or lower than the design value or different combination forms of the temperature and the water can be rectified to be within the process design and control range, and the shredding under the optimal working condition all the year round is realized;

4) the working condition parameter test and optimization of the product full formula smoked sheet are as follows: and (3) according to laboratory test data of the single-grade smoked sheets in the step (1), working condition tests are carried out by combining the grades of the fully formulated smoked sheets of the product, the optimal process quality and the process parameter with the lowest dust breakage consumption are comprehensively screened, and the process standards of high-grade, medium-grade and low-grade brands are established.

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