CN112956724A - Cut tobacco drying process parameter optimization method - Google Patents
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- 238000000034 method Methods 0.000 title claims abstract description 137
- 241000208125 Nicotiana Species 0.000 title claims abstract description 112
- 235000002637 Nicotiana tabacum Nutrition 0.000 title claims abstract description 112
- 238000001035 drying Methods 0.000 title claims abstract description 53
- 238000005457 optimization Methods 0.000 title claims abstract description 37
- 230000008569 process Effects 0.000 claims abstract description 111
- 230000004044 response Effects 0.000 claims abstract description 58
- 238000012360 testing method Methods 0.000 claims abstract description 45
- 230000001953 sensory effect Effects 0.000 claims abstract description 40
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- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 26
- 239000000463 material Substances 0.000 claims description 26
- 239000001301 oxygen Substances 0.000 claims description 26
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- A—HUMAN NECESSITIES
- A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
- A24B—MANUFACTURE OR PREPARATION OF TOBACCO FOR SMOKING OR CHEWING; TOBACCO; SNUFF
- A24B3/00—Preparing tobacco in the factory
- A24B3/04—Humidifying or drying tobacco bunches or cut tobacco
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- A—HUMAN NECESSITIES
- A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
- A24B—MANUFACTURE OR PREPARATION OF TOBACCO FOR SMOKING OR CHEWING; TOBACCO; SNUFF
- A24B3/00—Preparing tobacco in the factory
- A24B3/10—Roasting or cooling tobacco
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- A—HUMAN NECESSITIES
- A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
- A24B—MANUFACTURE OR PREPARATION OF TOBACCO FOR SMOKING OR CHEWING; TOBACCO; SNUFF
- A24B9/00—Control of the moisture content of tobacco products, e.g. cigars, cigarettes, pipe tobacco
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Abstract
The embodiment of the invention provides a cut tobacco drying process parameter optimization method, which comprises the following steps of: respectively carrying out single-factor tests on a plurality of process parameters to determine the value range of each process parameter; response surface optimization test step: designing a response surface optimization test by utilizing the value range of each process parameter, and acquiring the tobacco shred structure and sensory quality corresponding to each test in the response surface optimization test; and (3) comprehensive grading step: respectively determining the converted scores and the weights of the tobacco shred structures and the sensory quality corresponding to each test, and calculating the comprehensive score of each test according to the converted scores and the weights; determining process conditions: and analyzing the response surface optimization test by using the comprehensive score of each test to obtain the process conditions of the cut tobacco drying process. Meanwhile, a plurality of process parameters are optimized, the physical quality and the sensory quality of the tobacco shred quality are comprehensively considered, and comprehensive evaluation of the tobacco shred quality is taken as a response value, so that the method is comprehensive.
Description
Technical Field
The invention relates to the field of cigarette cut tobacco processing, in particular to a cut tobacco drying process parameter optimization method.
Background
The cut tobacco drying process is a key process in the cigarette cut tobacco production process, and the process task of the cut tobacco drying process is to remove part of moisture in the cut tobacco, enable the cut tobacco to have certain flexibility, improve the filling capacity and the processing resistance of the cut tobacco and meet the processing requirements of the subsequent processes, and on the other hand, to show the aroma style of the cigarette and improve the sensory quality. According to the difference of heat transfer principle, the two methods of drying the cut tobacco are mainly roller cut tobacco and airflow cut tobacco, wherein the roller cut tobacco is mainly used for heat transfer in a heat conduction mode, and the airflow cut tobacco is used for heat transfer in a heat convection mode. The TOWER air flow cut tobacco drier CTD (COMAS TOWER DRYER) is an air flow cut tobacco drier developed and researched by the Italy COMAS company, the working principle of the air flow cut tobacco drier is that high-temperature convection air is utilized to quickly dry part of moisture in cut tobacco, so that the moisture content of the cut tobacco at an outlet reaches the process requirement, the filling capacity and the processing resistance of the cut tobacco are improved, the sensory quality of the cut tobacco is considered, and the air flow cut tobacco drier is cut tobacco drier which is used in industry more in the 'twelve five' period. How to optimize the technological parameters to ensure that the comprehensive quality of the cut tobacco reaches the optimal level has not been reported yet.
Disclosure of Invention
Therefore, the invention provides a cut tobacco drying process parameter optimization method, so as to optimize the process parameters of the cut tobacco drying process.
According to a first aspect, an embodiment of the present invention provides a cut tobacco drying process parameter optimization method, including:
single factor experiment procedure: respectively carrying out single-factor tests on a plurality of process parameters to determine the value range of each process parameter;
response surface optimization test step: designing a response surface optimization test by using the value range of each process parameter, and acquiring the tobacco shred structure and sensory quality corresponding to each test in the response surface optimization test;
and (3) comprehensive grading step: respectively determining the converted score of the tobacco shred structure and the sensory quality corresponding to each test and the weight of the tobacco shred structure and the sensory quality corresponding to each test, and calculating the comprehensive score of each test according to the converted score and the weight;
determining process conditions: and analyzing the response surface optimization test by using the comprehensive score of each test to obtain the process conditions of the cut tobacco drying process.
The tobacco shred drying process parameter optimization method provided by the embodiment of the invention optimizes a plurality of process parameters simultaneously, comprehensively considers the physical quality and the sensory quality of the tobacco shred quality, takes the comprehensive evaluation of the tobacco shred quality as a response value, and is more comprehensive.
With reference to the first aspect, in a first implementation manner of the first aspect, the determining the value range of each process parameter by performing the single-factor test on each of the plurality of process parameters includes:
and respectively carrying out single-factor tests on the plurality of process parameters, and determining the value range of each process parameter according to the influence of each process parameter on the standard deviation of the moisture content of the cut tobacco drying outlet and the sensory quality.
With reference to the first embodiment of the first aspect, in a second embodiment of the first aspect, the plurality of process parameters includes one or more of: material flow, expansion joint process gas temperature, expansion joint process gas flow and oxygen content.
With reference to the first aspect, in a third embodiment of the first aspect, the tobacco thread structure comprises one or more of: the whole silk rate, the broken silk rate and the filling value.
With reference to the first aspect, in a fourth implementation manner of the first aspect, the designing a response surface optimization test by using the value ranges of the process parameters includes:
and designing a response surface optimization test according to the center combination design principle of Box-Behnken by using the value range of each process parameter.
With reference to the first aspect, in a fifth implementation manner of the first aspect, the analyzing the response surface optimization test by using the composite score of each test to obtain the process conditions of the cut-tobacco drying process includes:
establishing a response surface regression model by using the comprehensive score of each test, and verifying the response surface regression model;
and analyzing the response surface regression model to obtain the process conditions of the cut tobacco drying process.
With reference to the fifth embodiment of the first aspect, in the sixth embodiment of the first aspect, after the step of determining the process conditions, the method further includes: response surface regression model verification step: and performing a test by using the process conditions of the cut tobacco drying process, comparing the predicted value and the experimental value of the model, and verifying the effectiveness of the model.
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In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and other drawings can be obtained by those skilled in the art without creative efforts.
FIG. 1 is a schematic flow chart of a method for optimizing cut tobacco drying process parameters according to embodiment 1 of the present invention;
FIG. 2 is a graph showing the effect of material flow on the standard deviation of moisture content at the cut tobacco drying outlet and sensory quality;
FIG. 3 is a graph showing the effect of expansion joint process gas temperature on the standard deviation of moisture content at the cut tobacco outlet and sensory quality;
FIG. 4 is a graph showing the effect of expansion joint process air flow on the standard deviation of moisture content at the cut tobacco outlet and sensory quality;
FIG. 5 is a graph showing the effect of oxygen content on the standard deviation of moisture content at the cut tobacco exit and on organoleptic quality;
FIG. 6 is a graph of the response of Z ═ f (mass flow, expansion joint process gas temperature);
fig. 7 is a graph of the response surface of Z ═ f (material flow rate, oxygen content);
FIG. 8 is a graph of the response of Z ═ f (expansion joint process gas temperature, expansion joint process gas flow rate);
fig. 9 is a graph of the response of Z ═ f (expansion joint process gas flow, oxygen content).
Detailed Description
The following examples are provided to further understand the present invention, not to limit the scope of the present invention, but to provide the best mode, not to limit the content and the protection scope of the present invention, and any product similar or similar to the present invention, which is obtained by combining the present invention with other prior art features, falls within the protection scope of the present invention. The examples do not show the specific experimental steps or conditions, and can be performed according to the conventional experimental steps described in the literature in the field. The reagents or instruments used are not indicated by manufacturers, and are all conventional reagent products which can be obtained commercially.
Research shows that when the optimization of the CTD airflow cut-tobacco drying process parameters is carried out by taking a certain physical index (such as the standard deviation of the moisture content of a cut-tobacco drying outlet or a filling value) as a response value, actually when a certain process parameter is changed, the influence caused by the optimization is not that only one response value is changed, and if the process parameter optimization is carried out aiming at the filling value, the possible result is that the set of parameters enables the filling value to reach the optimal level, but the process parameter combination is not the best for the whole-cut-tobacco drying rate.
Based on this, the embodiment 1 of the invention provides a cut tobacco drying process optimization method, which is used for optimizing process parameters when a CTD airflow cut tobacco drying line of an N cigarette factory produces a certain brand H. Fig. 1 is a schematic flow chart of a cut tobacco drying process parameter optimization method according to embodiment 1 of the present invention, and as shown in fig. 1, the cut tobacco drying process parameter optimization method includes the following steps.
S101: single factor Experimental procedure
And (3) carrying out a single-factor experiment, analyzing the influence of each main process parameter (material flow, expansion joint process gas temperature, expansion joint process gas flow and oxygen content) on the standard deviation of the moisture content of the cut tobacco outlet and sensory quality, and determining the value range of each main process parameter.
1. Determination of material flow
Combining the production capacity of equipment, the material flow rates are 4000, 4200, 4400, 4600, 4800, 5000 and 5200kg/h respectively, the temperature of the fixed expansion joint process gas is 151 ℃, and the flow rate of the expansion joint process gas is 18000m3And h, drying the cut tobacco under the condition of 3 percent of oxygen content, and researching the influence of the material flow on the standard deviation of the water content of the cut tobacco at the cut tobacco drying outlet and the sensory quality.
2. Determination of expansion joint process gas temperature
The temperature of the expansion joint process gas is 145, 147, 149, 151, 153, 155 and 157 ℃, the fixed material flow rate is 4600kg/h, and the expansion joint process gas flow rate is 18000m3And/h, drying the cut tobacco under the condition of 3 percent of oxygen content, and researching the influence of the expansion joint process gas temperature on the standard deviation of the water content of the cut tobacco at the cut tobacco drying outlet and the sensory quality.
3. Determination of expansion joint process gas flow
The process air flow in the expansion joint is 17100, 17400, 17700, 18000, 18300, 18600 and 18900m3And/h, fixing the material flow rate of 4600kg/h, drying the cut tobacco under the conditions of the expansion joint process gas temperature of 151 ℃ and the oxygen content of 3 percent, and researching the influence of the expansion joint process gas flow rate on the standard deviation of the water content of the cut tobacco at the cut tobacco drying outlet and the sensory quality.
4. Determination of oxygen content
The oxygen content is respectively 1.0%, 2.0%, 3.0%, 4.0%, 4.5%, 5.0%, 5.5%, the material flow is fixed 4600kg/h, the temperature of the expansion joint process gas is 151 ℃, and the flow of the expansion joint process gas is 18000m3And drying the cut tobacco under the condition of/h, and researching the influence of the oxygen content on the standard deviation of the water content of the cut tobacco at the cut tobacco drying outlet and the sensory quality.
FIG. 2 shows the influence of the material flow on the standard deviation of the water content at the cut tobacco drying outlet and the sensory quality, and it can be seen from FIG. 2 that with the increase of the material flow, the standard deviation of the water content of cut tobacco at the cut tobacco drying outlet tends to decrease first and then increase, while the sensory score increases first and then decreases, and when the material flow is 4600kg/h, the sensory score reaches the maximum value. Therefore, the material flow is selected to be 4400 kg/h-4800 kg/h.
Fig. 3 shows the influence of the expansion joint process gas temperature on the standard deviation of the moisture content at the cut tobacco outlet and the sensory quality, and as can be seen from fig. 3, the standard deviation of the cut tobacco moisture content at the cut tobacco outlet is obviously reduced along with the increase of the expansion joint process gas temperature, when the process gas temperature is 145-151 ℃, the sensory score is increased along with the increase of the process gas temperature and then begins to be reduced, when the process gas temperature is 151 ℃, the sensory score reaches 91.2, and the process gas temperature is too high, so that the loss of flavor components in the cut tobacco is caused, and the sensory score is reduced. And combining the standard deviation data of the water content of the cut tobacco at the cut tobacco drying outlet, so that the temperature of the expansion joint process gas is selected to be 147-155 ℃.
FIG. 4 shows the effect of the air flow of the expansion joint process on the standard deviation of the moisture content at the cut tobacco outlet and the sensory quality, and it can be seen from FIG. 4 that the standard deviation of the moisture content of the cut tobacco at the cut tobacco outlet tends to decrease and then increase with the increase of the air flow of the expansion joint process, and the air flow of the expansion joint process is selected to be 17400 kg/h-18600 kg/h in combination with the sensory evaluation.
FIG. 5 shows the effect of oxygen content on the standard deviation of moisture content at the cut tobacco outlet and the organoleptic quality, and it can be seen from FIG. 5 that the standard deviation of moisture content at the cut tobacco outlet has no obvious regularity along with the increase of the oxygen content, the organoleptic score increases along with the increase of the oxygen content when the oxygen content is 1% -4%, and then starts to decrease, and the organoleptic score reaches 91 when the oxygen content is 4%, so the oxygen content is selected to be 2.0% -5.0%.
S102: response surface optimization test procedure
1. Response surface optimization experimental design
Based on a single-factor experiment, according to the center combination design principle of Box-Behnken, 4-factor and 3-level experiment design is carried out, and the result is shown in Table 1.
TABLE 1 response surface optimization experiment factor horizon
2. Experimental results of response surface
Multiple regression experiments were performed according to table 1 to study the relationship of each factor to tobacco shred structure and sensory score. The results are shown in Table 2.
TABLE 2Box-Behnken Experimental design and results
S103: and (3) comprehensive grading step:
determining the converted scores of the tobacco shred structure and the sensory quality according to the conformity degree of the tobacco shred structure and the sensory quality with the standard design value, determining each weight of the tobacco shred structure and the sensory quality by adopting a weighting method, synthesizing the converted scores of the tobacco shred structure and the sensory quality and the weights occupied by the converted scores, and calculating the comprehensive score of the tobacco shred quality.
Specifically, the cut tobacco structure and sensory quality conversion scoring criteria are shown in table 3. The cut tobacco structure and sensory quality weight distribution are shown in table 4.
TABLE 3 conversion scoring standard for tobacco shred structure and sensory quality
TABLE 4 tobacco shred structure and sensory quality weight distribution table
The comprehensive scoring results of the tobacco shred quality under each experimental condition are shown in table 5.
TABLE 5 tobacco shred quality comprehensive scoring results
S104: and (4) determining process conditions.
And analyzing a response surface experiment by taking the comprehensive score Z of the tobacco shred quality as a response value, and determining the optimal process condition of the CTD airflow tobacco shred drying.
1. Establishment and inspection of response surface regression model
And (3) carrying out data processing by taking the comprehensive score Z in the table 5 as a response value, deleting the insignificant items, and further optimizing the model to obtain a regression model equation:
Z＝92.77-0.065A+0.24B+0.11C-0.2D+0.24AB+0.45AD-0.48BC-0.51CD-0.25A2-0.93B2-0.3C2
in the above regression model equation, a represents the material flow rate, B represents the expansion joint process gas temperature, C represents the expansion joint process gas flow rate, and D represents the oxygen content.
TABLE 6 regression model analysis of variance
Note: indicates that the difference is extremely significant (p < 0.01); indicates significant differences (0.01 < p < 0.05).
As shown in the ANOVA Table 6, p < 0.0001 indicates that the model is extremely significant, and the mismatching term p is 0.7618 > 0.05 indicates that the model is not significant in mismatching, R2＝0.9016，R2 adj0.8295, the model is good for experimental fitting and has high reliability, and the regression equation can be used for predicting the response value.
As can be seen from Table 6, in the primary term of the model, B is extremely significant, D is significant, A and C are not significant, the interactive terms AD, BC and CD are extremely significant, AB is not significant, and the secondary term B is extremely significant2Very pronounced, A2，C2Obviously, the factors which are obtained from the values of the factors F and have the greatest influence on the comprehensive quality score of the cut tobacco with the response value are the expansion joint process gas temperature, the oxygen content, the expansion joint process gas flow and the material flow.
2. Analysis of interaction between factors
As can be seen from fig. 6, the flow rate and the oxygen content of the fixed expansion joint process gas are at 0 level, and the curve of the response surface is relatively flat, which indicates that the material flow rate and the temperature of the expansion joint process gas have relatively significant influence on the response value Z, the material flow rate is at a lower level, and the contour lines are relatively dense when the temperature of the expansion joint process gas is at a middle level, indicating that in this range, the change of the material flow rate and the temperature of the expansion joint process gas has a large influence on the response value Z, and the response value Z begins to decrease after reaching the maximum value as the material flow rate and the temperature of the expansion joint process gas continuously increase;
as can be seen from fig. 7, when the temperature of the fixed expansion joint process gas and the flow rate of the expansion joint process gas are at 0 level, the influence of the material flow rate and the oxygen content on the response value Z is very significant, and when the material flow rate is at a lower level, the response value Z continuously rises along with the reduction of the oxygen content;
as can be seen from FIG. 8, the response surface curve is steep when the flow rate and oxygen content of the fixed material are at 0 level, and it can be seen that the expansion joint process gas temperature and the expansion joint process gas flow rate have a very significant influence on the response value Z, when B is greater than 151, C is less than 18300, the contour lines are dense, which indicates that in this range, the change of the expansion joint process gas temperature and the expansion joint process gas flow rate has a large influence on the response value Z, and when the expansion joint process gas temperature is at a higher level, the response value Z starts to slowly decrease after rising to an extreme value along with the continuous increase of the process gas flow rate;
as can be seen from FIG. 9, the fixed material flow rate and the expansion joint process gas temperature are at 0 level, the oxygen content is at a lower level, and the response value Z starts to slowly decrease after rising to an extreme value along with the continuous increase of the expansion joint process gas flow rate.
3. Determination of optimum process parameters
The obtained response surface model is analyzed through a response optimizer, the optimal parameters of the CTD air flow cut tobacco drying process are 4400kg/h of material flow, the temperature of the expansion joint process gas is 150 ℃, the flow rate of the expansion joint process gas is 18600kg/h, the oxygen content is 2.0%, and theoretically, the comprehensive grade value of the cut tobacco quality reaches 93.57.
Step five: response surface regression model verification step:
and performing a CTD airflow cut tobacco drying verification experiment under the optimal process condition, wherein the experiment result is shown in a table 7, and converting and scoring are performed on each index of the table 7 to obtain a comprehensive cut tobacco quality score of 92.97 +/-0.46 which is basically consistent with a predicted value, so that the regression model is accurate, and the method for optimizing the CTD airflow cut tobacco drying process by applying the method is accurate and feasible.
TABLE 7 tobacco shred quality index values
It should be understood that the above examples are only for clarity of illustration and are not intended to limit the embodiments. Other variations and modifications will be apparent to persons skilled in the art in light of the above description. And are neither required nor exhaustive of all embodiments. And obvious variations or modifications therefrom are within the scope of the invention.
Claims (7)
1. A cut tobacco drying process parameter optimization method is characterized by comprising the following steps:
single factor experiment procedure: respectively carrying out single-factor tests on a plurality of process parameters to determine the value range of each process parameter;
response surface optimization test step: designing a response surface optimization test by using the value range of each process parameter, and acquiring the tobacco shred structure and sensory quality corresponding to each test in the response surface optimization test;
and (3) comprehensive grading step: respectively determining the converted score of the tobacco shred structure and the sensory quality corresponding to each test and the weight of the tobacco shred structure and the sensory quality corresponding to each test, and calculating the comprehensive score of each test according to the converted score and the weight;
determining process conditions: and analyzing the response surface optimization test by using the comprehensive score of each test to obtain the process conditions of the cut tobacco drying process.
2. The cut-tobacco drying process parameter optimization method according to claim 1, wherein the step of respectively performing single-factor tests on the plurality of process parameters to determine the value ranges of the process parameters comprises the following steps:
and respectively carrying out single-factor tests on the plurality of process parameters, and determining the value range of each process parameter according to the influence of each process parameter on the standard deviation of the moisture content of the cut tobacco drying outlet and the sensory quality.
3. The cut-tobacco drying process parameter optimizing method according to claim 2, wherein the plurality of process parameters include one or more of: material flow, expansion joint process gas temperature, expansion joint process gas flow and oxygen content.
4. A method of optimizing cut tobacco drying process parameters according to claim 1, wherein the cut tobacco structure comprises one or more of: the whole silk rate, the broken silk rate and the filling value.
5. The cut-tobacco drying process parameter optimization method according to claim 1, wherein the step of designing a response surface optimization test by using the value ranges of the process parameters comprises the following steps:
and designing a response surface optimization test according to the center combination design principle of Box-Behnken by using the value range of each process parameter.
6. The cut-tobacco drying process parameter optimization method according to claim 1, wherein the analyzing the response surface optimization test by using the comprehensive score of each test to obtain the process conditions of the cut-tobacco drying process comprises:
establishing a response surface regression model by using the comprehensive score of each test, and verifying the response surface regression model;
and analyzing the response surface regression model to obtain the process conditions of the cut tobacco drying process.
7. The cut-tobacco drying process parameter optimizing method according to claim 6, further comprising, after the process condition determining step:
response surface regression model verification step: and performing a test by using the process conditions of the cut tobacco drying process, comparing the predicted value and the experimental value of the model, and verifying the effectiveness of the model.
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