In view of the problem that the current threshing and redrying process parameters are solidified and difficult to adapt to the differentiated quality improvement needs of different quality tobacco leaves, the study aims to tap the potential of tobacco raw materials, enhance the use value and support the high-quality development of cigarette brands. Taking flue-cured tobacco of different grades of ‘Yunyan 97’ and ‘Yunyan 105’ from Luoping County, Yunnan Province in 2024 as experimental materials, manual sorting was conducted. High-quality raw materials were designated as the S module, and low-quality raw materials were designated as the X module. The potential of tobacco raw materials was explored by formulating sensory quality evaluation table, setting preset processing parameters, and constructing correlation analysis between sensory evaluation, chemical composition and process parameter control. The results showed: (1) When the S module adopted TS3 parameters, the total sugar, nitrogen-to-alkali ratio, and potassium-to-chlorine ratio increased by 6.71%, 3.13%, and 36.24% respectively compared to TS0, while chlorine content and sugar-to-alkali ratio decreased by 31.69% and 2.27% respectively, resulting in more balanced composition. In sensory evaluation, indicators such as aroma intensity and fragrance volume improved by 3.08%-17.54%, with overall scores rising by 7.91%. This improvement manifested as enhanced aroma intensity and fragrance volume, increased transparency, reduced irritation, stronger smoke satisfaction, and a lingering sweet aftertaste with natural throat moisture. (2) When the TX3 parameter was adopted in module X, the contents of reducing sugar, nicotine, potassium and potassium-chloride ratio increased by 3.90%, 4.89%, 5.50% and 72.76% respectively compared with TX0, while the chlorine content and nitrogen-alkali ratio decreased by 40.28% and 5.77%. The sensory score improved by 1.82%-20.00%, and the total score increased by 7.32%, showed characteristics such as enhanced fragrance, smoother smoke and less irritation, with a balanced overall performance. The reasonable setting of process parameters during tobacco redrying can balance the chemical composition of flue-cured tobacco, realize the differentiated effect of high-quality modules to preserve fragrance and enhance permeability, and low-quality modules to preserve fragrance and remove impurities. In the future, the production area and variety range can be expanded to establish a common use redrying process parameter system.