Reconstituted Tobacco Sheet Processing Equipment Rolling 180kg/h
1. General Statement
Reconstituted Tobacco Sheet Production Line By Rolling is one
complete group of equipment which makes full use of tobacco waste
such as tobacco stems, powder and dust etc. produced in cigarette
manufacturing process. It adopts special technical recipe and flow
to finally remake the waste into tobacco Sheet filament.
This production line has the advantages of small investment,
environment protection without pollution during manufacturing,
reducing cigarette production cost greatly and producing great
The production capability of it has specifications of 80kg/h,
180kg/h, 200kg/h, 400kg/h, 600kg/h, 800kg/h.
2. Working conditions:
2.1 Environmental temperature:10-40℃
2.2 Relative humidity: ≤85%
2.3 Altitude above sea level: ≤2000m
2.4 Power supply:3N-50Hz/TN-S 380V±38V 50Hz±1Hz
2.5 Inlet steam pressure of equipment: not less than 0.8Mpa
2.6 Inlet compressed air pressure of equipment: not less than
2.7 Inlet water pressure of equipment: not less than 0.2Mpa
2.8 Supplying material conditions: unpolluted and non-mildewed
tobacco stem and powder, with moisture content not more than 16%,
sand/ soil rate of tobacco stem not more than 2%, sand/ soil rate
of tobacco powder not more than 3%, the length of tobacco stem not
more than 20mm. Proportion rate of tobacco stem and powder
material: tobacco stem from 30% to 60%, tobacco powder from 40% to
70%.When inlet material has been dried outside the line, water rate
of the tobacco stem and powder entering grinder should be not more
than 10% and its purity is not less than 98%.
2.9 Viscosity of CMC is not less than 600 centipoises, liquid
mixture material should have no undissolved substance, materials
larger than 60 mesh are not permitted to come into the liquid
3. Main Technical Parameters
3.1 Production capacity:
Rate production capability is 80kg/h, 180kg/h, 200kg/h , 400 kg/h ,
600 kg/h, 800kg/h (moisture content of product is taken as 13%)
3.2 Quality indexes of finished product (recon tobacco):
thickness of cut-recon: 0.12mm±0.01mm
length of cut-recon: 30mm-80mm
width of cut-recon: (0.8-1.0)mm±0.1mm
water content of cut-recon finished product: (13±1)%
whole cut-recon percentage: not less than 90%.
Sheet grammage tensile strength, folding strength, tear strength,
water resistance, softness should comply with the regulations of
The total power consumption of the whole line:210KW
The dimension of factory building the whole line needed (optimized
4. Technical flow and characteristics:
4.1 The technical flow chart
4.2 The main characteristics of Recon Production Line:
(1) Pre-treatment section adopts the working procedures of
vibratory sieving, iron removing and pneumatic classification, to
effectively eliminate the impurity of the raw material so as to
raise the purity of the materials.
(2) The tobacco stem and powder adopts time-sharing drying on
line and automatic classification storage. The stem and powder are
proportioned automatically under the accurate control of screw
electric scale with its error less than 2%. What’s more, it is
convenient to adjust the proportion between the tobacco stem and
powder. The drying of tobacco stem and power adopts the drying
cylinder with dehydration capacity is more than 6%. After drying,
the material has moisture of not more than 10%, which is easy to be
(3)The material pneumatic conveying system and grinded
material pneumatic conveying system both adopt negative pressure
operation, two-stage dust discharging, which improves the
environment of workshop.
(4) Stem bin and powder bin both have been installed with
material positioning sensor, which achieves an automatic start/stop
of equipment through the signal interlocking.
(5) The measuring of liquid and solid material all adopt
decrement electronic scales .It can control the accuracy of
materials output through frequency conversion control. It can
ensure the moisture accuracy ±2% after blending.
(6) It adopts advanced technology in stem defibration. The
tensile strength of recon will raise over 100% after adding stem
fiber. It raises greatly the valid utilization rate of the sheet
which is ≥95%.
(7) The adoption of the second time crimping technology can
raise the filling value of cut-recon. After the drying &
crimping cylinder, there is a cooling device which cools down
temperature of recon and helps shape-forming of the product
(8) It sets up moisture automatic control system. It can
assure the moisture deviation ≤±1.5% after cutting. The moisture
deviation of finished product is not more than ±1%.
(9) The control system is set up according to different
control level; it is practical and advanced, easy for operation.
a. The control system has manual and auto operating modes. Manual
operation is used in maintenance and on-site emergency treatment.
Auto mode is used for normal production.
b. The system adopts PLC controller with high reliability and good
brand low-pressure electrical components, and make the whole line
operate automatically by start-stop in sequence control and by
conditional interlocking. It gives real-time warning and indication
for over current, lack of phase, short circuit etc. It is easy to
maintain and repair. The system has high reliability.
c. The accuracy of measuring and blending of powder and liquid
material can reach 99%. The blending ratio can be flexibly
adjusted. The technology and production capacity have good
d. As to those sections with high requirements for flow, speed,
moisture and temperature, it adopts intelligent instruments, such
as frequency control, temperature control apparatus, dynamic
measuring electronic scales and moisture apparatus etc, it can be
monitored and supervised locally, and it is also supervised by the
upper-digit computer in concentration.
e. The upper-digit computer can achieve the concentrated
supervision in order to facilitate the management on-line. It can
generate production report forms showing material consumption and
product statistics for data storage.
5. The system composition and functions
It consists of Raw material purifying system, Grinding and storing
system, Powder and liquid material proportioning system, Rolling,
drying & cutting system, Second time drying and crimping
system, Electrical control system and General engineering system.
There are options of fiber & glue proportioning system, long
stem grinding system available for customers according to the raw
material and special technical requests.
5.1 Raw material purifying system
5.1.1The system composition and functions
This system mainly consists of Quantitative screw conveyer, Rotary
vibration sieve, Vibratory conveyor, Drying cylinder, Magnetic iron
remover, Two-way screw conveyer, stem bin and powder material bin,
pneumatic conveying & dust removing system etc.. It can
complete the working procedures of quantitative feeding of stem and
powder, sieving and cleaning, iron removing, pneumatic conveying
and classification, automatic classification and storage of stem
(1) It sets up multiple working procedures for material
purifying to assure the purity of material ≥98%.
(2) The vibratory sieving device adopts rotary vibration
sieve to eliminate the impurity ＞2 mesh and < 80 mesh.
(3) The pneumatic conveying system adopts negative pressure
operation and two - stage dust removing system. It makes a better
environment in workshop.
(4) It adopts automatic classification and storage of stem
and powder, sensors indicating material high and low level are
interlocked with the previous equipment to achieve automatic
5.2 Grinding and storing system
5.2.1The system Composition and functions
This system mainly consists of L-type screw conveyer, Screw
electronic scale, Screw conveyer, two-way screw conveyer, Grinder,
CMC feeder, Cyclone material discharging airlock, Dust remover,
Powder bin and pneumatic conveying and dust removing system. It can
complete the working procedures of the automatic proportioning of
powder and stem, the quantitative adding of CMC, iron removing,
grinding and grinded powder storage.
(1) It adopts screw electronic scale for proportioning of
tobacco stem and powder automatically, static accuracy≤2%;
(2) Install two grinders in parallel to make sure that repair
or maintenance of one grinder would not affect production. The
grinding particle size can reach 40-120 meshes, flow rate 400kg/h.
(3) The pneumatic conveying system adopts negative pressure
operation. It makes a good environment in workshop.
(4) The grinded powder bin is equipped with a sensor
indicating the height of material, and is interlocked with the
upstream machines to achieve automatic start/stop.
5.3 Powder and liquid material proportioning system
5.3.1The system composition and functions
This system mainly consists of L-type screw conveyer, electronic
scale for powder, electronic scale for liquid, liquid proportioning
tank, Agitator, Extruder etc. It can complete the working
procedures of the liquid proportioning, powder and liquid automatic
proportioning and agitation, extruding with the brute force.
(1) It adopts weight drop electronic scale for proportioning
of the powder and liquid material, a frequency converter for
control of the material feeding accuracy. Proportioning inaccuracy:
5.4 Rolling, drying & cutting system
5.4.1The system composition and functions
This system mainly consists of roller, belt conveyor, combined
recon dryer, cooling belt conveyor, cutter etc. It can complete the
three times of working procedures of 3 stages of recon sheet
rolling, fast drying & cooling, and recon tobacco cutting as
per technical requirements.
(1) The roller is made of rare earth alloy cast iron by
founding, the thickness of the hardening rolling surface layer
reaches up to 8mm, and the surface of the roller is processed by
special wearing-resist technology and the roller can be used
repeatedly after finely wearing processing.
(2) Tobacco sheet is formed though three rolling and pressing
processes to ensure the uniformity of material after adding fiber.
(3) The combined recon drier adopts the combined drying mode
of electric heating and steam heating, and hot air circulating as
well, which saves energy and improves the physical quality indexes
of recon tobacco.
5.5 Second time drying and crimping system
5.5.1The system composition and functions
This system mainly consists of vibratory conveyer, drying &
crimping cylinder, cooling cylinder, vibratory sieving conveyer,
weighing scale etc. It completes the working procedures of second
time drying, crimping, cooling, shape forming of recon tobacco and
scaling of finished product for packing.
(1) This device can effectively improve the filling value of
cut recon up to ≥3.5cm3/g.
6. Electrical control system
Field bus control
Industry Ethernet model
Central control model
6.1 The system composition and functions
The electronic control system consists of electric drive control
subsystem, proportion control subsystem and moisture control
subsystem. It achieves automatic control over all equipment of the
whole line and control operating parameters. And there are options
of local centralized control mode, field bus mode and industry
Ethernet mode, etc. according to customers’ requirements.
6.2 System configuration
(1) It adopts S7-300 for PLC.
(2) Low voltage electronic components uses SIEMENS, MOELLER,
(3) Frequency varied device and soft start device adopts
(4) Field bus adopts SIEMENS ET-200S.
(5) Industry Ethernet adopts SIEMENS PROFINET.
(6) HMI adopts SIEMENS MP370.
(7) Upper computer supervision and control software adopts
All the configuration above can choose other brand according to the
7. Optional System
Fiber scatter device
Fiber glue proportioning system
7.1 Fiber & glue proportioning system
The fiber & glue proportioning system is the latest technology
in rolling and pressing tobacco sheet field, this technology can
effectively improve the physical and chemical index of tobacco
sheet. It can improve the effectiveness rate of tobacco sheet silk
by 30%, and improve filling rate from 3.5m3 /g to 3.8m3 /g. So the economic benefits is outstanding for selecting this
7.1.2System composition and functions
This system mainly consists of fiber scatter, reaction pot,
extruder, drying device, adding glue machine etc.. It can complete
the working procedures of the solution and dewatering of the fiber
panel and manufacture of sheet glue.
7.1.3Main function index and technical parameters
(1)Decomposing rate of wood pulp fiber: ≧95%
(2)Production capacity of finished fiber glue: ≧200kg/h
(3)Mixing proportion of fiber:1-5%
7.2 Long stem rough grinding system
This system is used to pre-treat long tobacco stems with length
more than 20mm, and to grind those stems into short stems with
length less than 15mm in order to meet the demands of production on
7.2.2System composition and functions
This system mainly consists of grinder, cyclone material collecting
device, spiral conveyor, dust removal device and wind conveying
system. It can complete the work of grinding the long stems into
short ones with length less than 15mm.
7.2.3Main technical parameters
(1) Production capability:400kg/h
(2) Not less than 95% tobacco stems length after grinding
is ≤15 mm
Tobacco stem viscose preparation system
Tobacco stem viscose preparation system is
the new technology by our new research and development, it mainly
decompose the fiber in the stem and add sugar and sheet glue and
other material according to the proportion and then manufactured
the tobacco stem viscose. It can replace the existing wood pulp
fiber sheet glue, compare to wood pulp fiber sheet glue, under the
same condition of enhancing sheet strength, it can greatly reduce
the production cost and reduce the influence of tobacco sheet
7.3.2System composition and function
The system mainly consists of defibrator, sugar material pot,
proportion pot, glue storage pot, liquid material conveying and
measurement system. It can finish the functions of the stem
defibration, liquid material measurement, proportion, storage and
7.3.3 Main technology indexes
Production capability: 150kg/h
Defibrator capacity: 150kg
Proportion pot capacity: 700kg(working capability 550kg)
Working pot capacity: (working capability 550kg )
Water consumption: 150kg/h
Economic benefits analysis of rolling process obacco sheet
1.Material formulation and cost
Liquid material 1
Liquid material 2
Liquid material 3
Liquid material 4
Unit price of FD sheet filament(yuan/Kg )(the output of the FD
filament is calculated in terms of 950Kg)
2.Manufacturing costs( every day two shifts, calculating in
260 days for one year )
Annual amount(Ten thousand yuan)
Sparepart& maintenance expenses
Fuel and power costs
Technical training fee
3.Total cost 5.72yuan/Kg
4.Economic benefits analysis
The direct economic benefit can be calculated by the following
W = 1000×M×N×Qe×(Y1－Y)
W---Value created from the adding of tobacco sheet(yuan )
M--- Efficient utilization rate of sheet calculating in terms of
N—Efficient operation rate of equipment calculating in terms of 90%
Qe--Quantity of sheet added into
tobacco silk(ton) in one year. Calculating in one day 2 shifts,
every shift is 1.6ton, calculating in every year 260 workdays,
Y1-- Price of some grade tobacco leaf replaced by sheet (yuan/kg).
Calculating in terms of 16 yuan/kg.
Y--- Cost of sheet , calculating in terms of 5.72 yuan/kg
W = 1000 * 95% * 90% * 832 *(16 - 5.72)= 0.7313million
5.Investment recovery period:
The investment for one 200kg/h sheet production line is about 12
million yuan, so the investment recovery period is : 12 million