Abstract:
Lu'an Guapian Tea (also called melon seed) is one type of green tea from Liu'an County in Anhui Province, China. Among them, baking is one of the most important processes in tea processing. Its baking quality can dominate the quality of tea, due to its baking process being different from other famous green tea. It is still lacking in continuous baking equipment, specifically for the Lu'an Guapian Tea. The traditional drum baking machine cannot fully meet the requirements of large-scale production at present, such as the high broken tea rate, poor baking quality, and insufficient aroma. In this study, a drum-type tea baking machine was designed using EDEM software, according to the baking process of the Lu'an Guapian Tea. The crawler-type ceramic belt was used as the electric heating element and then installed close to the outer wall, in order to reduce the thermal resistance. The frequency conversion speed was regulated suitable for the tea products in different periods; Dynamic analysis was carried out to further clarify the motion state of tea in the drum during baking. The tea particles were also moved periodically in the drum. The periodic motion of the tea particles in the drum was composed of three stages: contact, take-up, and drop. The force analysis of the tea particles in the three stages was carried out to establish the dynamic equation. There were influencing factors on the broken tea rate and baking quality, such as the rotation speed of the drum, the helix angle of the guide vane, the number of the guide vane, and the width of the guide vane. The virtual prototype was constructed by SolidWorks software. The particle model of the tea material was established by EDEM software. A numerical simulation was performed on the baking process of the tea particles in the drum. There was a significant relationship between the rotation speed of the drum, the spiral angle of the guide vane plate, the number of the guide vane plate, the width of the guide vane plate, as well as the average speed and average force of the tea particles. The key influencing factors were determined by the movement of the tea particles, even the breaking rate and quality of the tea after baking. Taking the raw tea the Lu'an Guapian Tea as the experimental material, a three-factor and three-level quadratic rotation orthogonal test was carried out to optimize the key structural parameters. The broken tea rate and sensory score were taken as the evaluation objectives, while the drum speed, the spiral angle of the guide vane, and the number of the guide vane were the main factors. The results showed that the primary and secondary influencing factors on the baking were: the drum speed, the spiral angle of the guide vane, and the number of the guide vane. Design Expert 13.0 was used for the regression analysis of the experimental data. An optimal combination of the parameters was: the spiral angle of the guide vane plate was 6°, and the number of the guide vane plates was 5. The better quality of the tea baking was achieved at the drum speed of 24 r/min. The prototype test was carried out to verify before and after optimization. The broken tea rate and sensory score were changed from 5.86% and 86.41 points to 4.82% and 92.1 points, respectively. The relative error between the predicted and the test was less than 5%. The finding can also provide a theoretical reference to optimize the tea-baking machine.