SPECIFICATION
The technology for the production of cut tobacco and expanded stem includes the following main technological processes:
- Moistening of leaf / unprocessed tobacco stem, as well as cleaving and saucing of leaf tobacco
- Separation of leaf tobacco
- Mixing of different varieties of leaf tobacco / untreated tobacco stem
Crimping an untreated tobacco stem
- Cutting tobacco leaf / untreated tobacco stem
- Conditioning of cut tobacco / cut tobacco stem
- Drying shredded tobacco / shredded tobacco stem
Dosage of expanded stem in cut tobacco mix
- Separation of the expanded tobacco stem
- Mixing cut tobacco / expanded tobacco stem
- Aromatization of cut tobacco / expanded stem
- Mixing cut tobacco / expanded tobacco strand
- Packing in boxes S-48
The high-tech line provides for the possibility of both processing cutting tobacco and untreated tobacco stem of high quality with a capacity for shredded tobacco 1500 kg / h, for expanded tobacco vein 700 kg / h
- Moistening of leaf / unprocessed tobacco stem, as well as cleaving and saucing of leaf tobacco
In the primary for preliminary moistening, cracking and saucing of leaf tobacco, as well as moistening of an untreated tobacco stem, a modernized Drum for cracking, conditioning and saucing LEGG AMF (item 3) is installed, namely, additional pins and paddles are installed in the drum according to the principle of Hauni conditioning drums , as well as additional nozzles were installed for better moistening and applying the sauce solution to leaf tobacco, which made it possible to improve the quality of processes and minimize the number of rejects. In addition, modernization has been carried out, which, if necessary, allows the number of drum revolutions to be reduced to 1.5 rpm, which has a positive effect on moisturizing the untreated tobacco stem. The processing of leaf tobacco and untreated tobacco stem is carried out alternately.
For preliminary moistening and saucing, leaf tobacco / untreated tobacco stem is fed to the unpacking table (pos. 1) on which the leaf tobacco is fed in layers from C-48 boxes with a layer thickness of not more than 150 mm. Raw materials are fed by means of an inclined belt conveyor (pos. 2).
The drum for splitting, conditioning and saucing (item 3) is a cylindrical drum made of stainless food steel with pins for breaking and blades for gentle breaking of tobacco / untreated tobacco stem in order to minimize losses during the breaking process, mounted on 4 rollers at an angle of 3 degrees, driven in rotation from a geared motor through a belt drive. The installed frequency converter allows you to adjust the drum speed in a wide range. There is a system for preheating before starting work, as well as circulating warm air during operation.
Saucing of leaf tobacco is carried out by means of a previously prepared sauce solution heated to a temperature of 55C and mixed using a standard mixer in the sauce kitchen (item 52). The flavoring solution is fed to the leaf tobacco through two-component nozzles, made in Germany. The design of the drum makes it possible to moisten: leaf tobacco from 10.0% to 22.0%; expanded tobacco vein from 11.0% to 36.0%, while the maximum steam demand is 400 kg / h.
- Separation of leaf tobacco
The separation of the humidified tobacco leaf is carried out by means of a separator in the air stream, which allows adjustment by means of adjustment by the technological window. At this stage, the separation of heavy organic impurities occurs. The moistened leaf tobacco is fed by means of a vibratory conveyor (Pos. 4), then it is transferred to the separator (Pos. 5), after which, by means of a pneumatic line (Pos. 6), it is fed to the tangential sluice (Pos. 7), which in turn produces portioned feed to belt conveyor (Pos. 8). Excess air with dust particles is transferred to the aspiration filter (pos. 53).
In the case of processing an untreated vein after the conditioning drum, the moistened raw material is fed to an inclined belt conveyor (Pos. 9), and then, through an inclined belt conveyor (Pos. 10) and a transverse loading carriage (Pos. 11), it enters the silo-mixer (Pos. 12). ).
- Mixing of different varieties of leaf tobacco / untreated tobacco stem
The line contains two silos-mixers (item 12) located parallel to each other, which are loaded alternately. In these silos-mixers, tobacco leaves / raw tobacco stem are blended by grade. They are also used for maturation, moisture redistribution and deeper impregnation with sauces. The volume of each silos-mixers is: 2000 kg for leaf tobacco; 1700 kg for untreated tobacco stem.
3.1 Crimping untreated tobacco stem
Unloading from the silos-mixers is carried out alternately onto the conveyor belt (Pos. 13), which ensures a continuous process. During transportation, the moistened raw material is transferred through a magnet (Pos. 14). In the case of leaf tobacco processing, the wetted raw material is transferred to the tobacco cutting machine by means of a belt conveyor.
The retractable inclined belt conveyor (Pos. 17) allows you to reorient the flows without loss of time in order to make an expanded tobacco stem. After the inclined belt conveyor, the moistened untreated tobacco strand is fed by means of a vibro-conveyor (pos. 18) to the HT tunnel from Hauni (pos. 19) for additional heating and conditioning, after which it is crushed on the FWE Quester rolling machine (pos. 20). The rolling device allows you to pass a vein through two metal rollers with an adjustable gap between the rollers from 0.5 mm.
- Cutting tobacco leaf / untreated tobacco stem
After conditioning, the stem is transferred to the KTV-2 dispenser box (Pos. 22) by means of a belt conveyor (Pos. 21). The dispenser box is designed for the accumulation of crimped stem and the uninterrupted operation of the tobacco cutting machine, Unicutter (Pos. 25).
Tobacco cutting machine Unicutter -allows you to cut a tobacco stem by means of a rotary knife drum with a cutting width of 0.1 mm and more, productivity up to 700 kg / h, moisture content from 31.0% to 37.0%. Further, the cut stem is fed for conditioning by the system of belt conveyors (Pos. 23; 24; 27).
- Conditioning of cut tobacco / cut tobacco stem
Conditioning is carried out in the HT-63 tunnel (Hauni) (pos. 28) by supplying steam at a pressure of 6 bar, adjustable up to 400 kg / h). In the HT tunnel, there is a 1.0-5.0% increase in moisture content, expansion and fiber separation.
- Drying shredded tobacco / shredded tobacco stem
After conditioning, the cut tobacco / expanded stem is fed through the loading vibratory conveyor to the KLK-4 (Hauni) drying drum (Pos. 29). This drum is designed to dry cut tobacco / expanded stem. During the drying process, the moisture content of the cut tobacco / expanded stem is brought to the target moisture content, which corresponds to 13.5-15%.
Drying takes place due to the supply of water vapor with a pressure of 6 bar to special steam lines inside the drum, which serve as blades for uniform transport inside the drum and a heat jacket, due to which moisture is removed from the product. Also, the drum is equipped with an air heating system with its subsequent injection into the drum cavity.
6.1 Dosage of expanded stem in cut tobacco mix
Unloading of dried cut tobacco is carried out by means of a vibrating conveyor (Pos. 30) with subsequent transfer to a system of belt conveyors (Pos. 33; 36) and a loading adaptation (Pos. 37) into a two-level silo with two horizontal belt conveyors STL (Pos. 38 ). in parallel, through the dispenser box (pos. 31), a predetermined dosage of the vein is made into the cut tobacco mixture. The regulation of the vein supply is carried out by means of a frequency converter and allows dosing of the expanded stem up to 40%.
- Separation of the expanded tobacco stem
The expanded stem (Pos. 30), unloaded from the vibratory conveyor, than fed into the separator. (Pos. 32) In it, uncut stem particles not exceeding 2.0% of the total mass are separated, then, by means of a pneumatic route (Pos. 34), they are transferred to a tangential sluice (Pos. 35) in which dust is separated from the main product. This section also serves as a cooling system in which the temperature drops from 75 degrees to 26 degrees and the volumetric elastic properties are fixed. The exhaust air with the separated dust is conveyed via a pneumatic line to the aspiration filter (Pos. 54). Further, by the system of belt conveyors (Pos. 3 3; 3 6), the expanded vein is fed to the loading adaptation (Pos. 37).
- Mixing cut tobacco / expanded tobacco stem
From the loading adaptation, the product enters the two-level Silo with two horizontal belt conveyors STL, (pos. 38) in which the supplied cut tobacco / expanded stem is mixed and cooled to ambient temperature. The presence of two horizontal parallel conveyors allows high-quality mixing of the processed product, achieving complete cooling to ambient temperature, as well as making experiments of any kind with small-volume batches.
- Aromatization of cut tobacco / expanded stem
Silo unloading is carried out by a system of belt conveyors (Pos. 39; 40), as well as a vibrating conveyor made of stainless steel (Pos. 41) with subsequent feeding into the aromatization drum (Pos. 42). The aromatization drum is made of stainless food-grade steel, mounted on four rollers driven by a geared motor and equipped with a two-component nozzle (air / liquid) for supplying the aromatization solution. The drum cavity is equipped with stainless steel pins for gentle mixing. At the outlet, the drum is equipped with an air intake protected by a mesh to remove fine dust particles, which is transferred by means of a pneumatic line to the aspiration filter (Pos. 54). The aromatization drum serves for uniform aromatization of the cut tobacco, uniform mixing with an added expanded stem, removal of fine dust particles and transportation. The fragrance solution is pre-prepared in the fragrance station (pos. 43) from which it is fed to the two-component nozzle.
The aromatization drum has been modernized in terms of supplying warm air to the drum cavity if additional moisture removal from the expanded stem is required, which also allows an additional increase in productivity by 200-250 kg / h.
- Mixing cut tobacco / expanded tobacco strand
After the aromatization process, the cut tobacco / expanded stem is fed into the silos-mixer (Pos. 49) by a system of belt conveyors (Pos. 44; 45; 46; 47) and a transverse loading adaptation (Pos. 48). At the outlet of the aromatization drum, the belt conveyor (Pos. 44) is equipped with an in-line moisture analyzer that allows you to regulate the moisture content of the final product.
In the silos-mixers (pos. 49), uniform mixing and moisture redistribution occurs with a deviation of +/- 0.3%. The capacity of the mixer silo is 2700 kg.
Packing in boxes S-48
The unloading of the silos-mixer is carried out by means of a belt conveyor (Pos. 50), followed by loading into the C-48 box.
The primary is equipped with a GARDNER DENVER screw compressor and a 500lit compressor receiver. The primary is controlled locally on the main pieces of equipment.