The volume of SMW stem increases significantly by superheated steam & microwave expansion and homogenizing techniques by utilizing stems, which providing a new formula module with characteristic of homogenization, harmonization, compatibility, comfortable taste, and gentle.
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- Technical advantages
- Product Features
- Product Application
Comparison
between stem & SMW stem, and traditional stem shred and SMW stem shred
Stem raw material: this technology can be utilized in processing long stem, short stem, new stem and old stem with a wide adaptability. Superheated steam-microwave expansion: steam/microwave energy ratio can be set to suit for different types of stem to get a consistent quality and appearance. With synergistic effect of steam and microwave, stem will have a rapid dehydration, with high processing intensity, low flavor release level, and macromolecules like hemicellulose will be pyrolyzed. Cutting: expanded stem can be cut into different forms based on requirement, such as flake, slice, granular, and put them into cigarette formula application after functional treatment.
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Table 1: expansion technology comparison between new type stem and traditional ones
Ltem |
Traditional roll drying |
Traditional pneumatic drying |
SMW stem technology |
Process |
Cutting and expansion |
Cutting and expansion |
Expansion and cutting |
Energy transfer |
Conduction+ convection |
convection |
Radiation+ convection |
Process temperature |
80-140℃ |
140-350℃ |
140-230℃ |
Processing time |
3-5min,relatively controllable |
<5s,uncontrollable |
13-638s,Preciselycontrollable |
Oxygen environment |
Oxygen content21% |
Oxygen content<10% |
Oxygen content<10% |
Reaction types |
Oxidation reaction and compound reaction |
It doesn’t have a chance to have a reaction. |
Decomposition reaction |
Stem fraction |
increase |
No change |
decrease |
Treatment effect |
Little effect on organ sensory, poor expansion effect |
Little effect on organ sensory, preferable expansion effect |
good effect on organ sensory, good expansion effect |
Significant expansion effect: macroscopic volume increases 2-6 times; micro-cavity of vascular tissue expands, clearance increases significantly.
Table:Electron micrograph before/after stem is expanded Good purification effect: macromolecules pyrolyze before they are turn into offensive odor, which tasted more purely. Good processing performance: expanded stem has a better permeability and flexibility to bearing higher mechanical processing intensity. Shapes, such as strip, flake, and shred, have been developed to meet different requirements from customers. Good compatibility: SMW stem shred has improved in offensive odor, irritation, and after taste compared with traditional stem slice, and organ sensory is better than traditional stem slice. Good carrier features: porous and multi-cavity structure of SMW stem makes it have a good carrier function, which allows tobacco extract and herbal extract entering the formula effectively. Mimicry with tobacco shred: Particularly, the shred sample is not only similar to tobacco shred, but also the shred shape at a mimicry level.
High uniformity in blending: compared to traditional stems shred, blending uniformity of SMW in cigarette increase from 71.53% to 84.62%, with a 13.09% increase. Significant tar and harm reduction: with same blend ratio, reduction of tar and CO release for SMW shred is superior to traditional stem shred.
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GL has built a 300kg/h pilot line in Shantou (excluded cutting), which has achieved a continuous and stable operation, accumulated extensive experience, cultivated a professional technical team.
Based on the pilot line, Guangdong GL has the capability to produce 2000kg/h. Annual output can exceed 4000t based on 251 working days, 8h for each shift to meet large scale requirement from cigarette company.
Guangdong GL has carried out many types of cutting test on different types of cutters, including straight blade, straight blade with incline angle, curved horizontal blade, and rotary type. Cutting process is matured, which provide necessary conditions to SMW application.
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Table:SMW cutting testing data
机型 |
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切丝宽度 |
刀门压力 |
刀辊转速 |
刀门高度 |
NQ13 |
一切 |
0.50mm |
5.5bar |
400r/min |
30mm |
二切 |
0.90mm |
5.2bar |
400r/min |
30mm |
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SQ216D |
一切 |
0.50mm |
40kN |
250r/min |
65mm |
二切 |
0.50mm |
20kN |
280r/min |
65mm |
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SQ315 |
一切 |
1.00mm |
53kN |
300r/min |
63mm |
二切 |
0.22mm |
23kN |
300r/min |
63mm |
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SQ317G |
一切 |
0.90mm |
57kN |
295r/min |
60mm |
二切 |
0.18mm |
25kN |
220r/min |
70mm |
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SQ38A |
一切 |
0.70mm |
7.0bar |
200r/min |
70mm |
二切 |
0.30mm |
2.6bar |
442r/min |
100mm |
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SQ317G |
一切 |
0.25mm |
70kN |
62.9% |
73mm |
二切 |
1.20mm |
70kN |
65.0% |
73mm |
Filling ratio of SMW is high, and after it is applied into cigarette, which can reduce the tobacco shred amount tremendously.
Table:SMW applied into cigarette and its technical economic effect
Item |
Value |
Item |
Value |
Cigarette circle |
24.2 |
Raw material use amountfor single case before blending |
33.288 |
Cigarette length |
60 |
Raw material use amountfor single case after blending |
31.259 |
Filling value of tobacco shred |
4.2 |
Tobacco shred use amountfor single case after blending
|
28.417 |
Filling value of traditional stem shred |
6.5 |
SMW use amountfor single case after blending |
2.842 |
Filling value of SMW |
7.2 |
Tobacco raw material saving amount for single case |
2.03 |
Blending ratio of SMW |
10% |
Tobacco leaf saving amount for single case |
4.871 |
Volume of cigarette |
2.796 |
Tobacco leaf Saving amount per kilo SMW |
1.714 |
Theoretical filling value after blended |
4.47 |
Tobacco leaf Saving amount per case compared with same ratio of traditional stem shred
|
0.41 |