Smoke flavoring production technology

The primary method of obtaining smoke flavorings is the pyrolysis of wood (mainly hardwoods), followed by condensation of the smoke in an aqueous medium. An important stage is the removal of tar and resinous substances from the aqueous condensate. During storage at temperatures of 5…35 °C, the condensate remains relatively stable in composition for several years.

Technological scheme

The technological scheme of producing water-based smoke flavorings includes the following steps:

– pyrolysis of wood;
– sorption of the smoke–air mixture by the water layer;
– filtration of the smoke water condensate;
– maturation of the smoke water condensate for 7–10 days in special tanks;
– decantation (separation of the solid phase from the liquid by mechanically draining the solution from the sediment);
– final filtration and packaging of the finished flavoring.

By adjusting the parameters of the sorption process, it is possible to obtain smoke condensates of stable quality with varying content and ratios of the main smoke components.

Production equipment

A unit for producing smoke flavoring generally consists of:

– smoke generator
– scrubber or absorber
– fan
– water pump
– cooling system
– control panel

Manufacturing process

Smoke from the smoke generator is directed into a scrubber or absorber, where volatile products of wood pyrolysis are absorbed into the circulating water within the system’s designated circuit. The smoke, purified by more than 90% of pyrolysis products, is released into the atmosphere. The liquid is then pumped into a settling tank, cooled to room temperature, and filtered.

Units for producing water-based smoke flavoring may consist of several scrubbers (absorbers) connected in series. A multi-stage purification system for the smoke liquid may also be used, involving several settling tanks in which the smoke liquid undergoes sequential purification.

Varieties of water-based smoke flavorings

Based on the technology used, there are several types of water-based smoke flavorings:

– blends of individual condensate fractions
– modified smoke flavorings
– smoke flavorings enhanced with additional components

Mixtures of individual condensate fractions are obtained by distilling complete condensates to separate individual fractions, followed by their blending. Depending on the proportion and composition of the individual fractions, it is possible to regulate the desired effect on the taste, color, and aroma of the smoked product.