Method for producing a material sheet containing alkaloids

Abstract

The present invention relates to a method for producing a sheet of material containing alkaloids, the method comprising the steps of: ○ providing a slurry comprising a material containing alkaloids, an aerosol former and water; ○ extruding the slurry; ○ collecting the extruded slurry in a storage tank having a plurality of outlets; ○ providing more than one matrix sheet comprising fibres; ○ supplying the slurry from the plurality of outlets so as to form a plurality of slurry strips on the more than one matrix sheet comprising fibres to form more than one sheet of material containing alkaloids.

Description

Technical Field

[0001] The present invention relates to a method for producing a cast sheet of a material containing alkaloids. Background Art

[0002] Specifically, the material containing alkaloids is a homogenized tobacco material, which is preferably used in aerosol-generating articles (such as cigarettes or "heat-not-burn" tobacco-containing products).

[0003] Today, when manufacturing tobacco products other than tobacco leaves, homogenized tobacco materials such as cast leaves or reconstituted tobacco are also used.

[0004] In "heat-not-burn" aerosol-generating articles, the aerosol-forming matrix is heated to a relatively low temperature to form an aerosol, but the tobacco material is prevented from burning.

[0005] The homogenized tobacco material is produced by mixing different components (including tobacco powder) to form a tobacco slurry. In addition, the slurry usually contains fibers, such as cellulose fibers, in addition to the fibers contained in the tobacco. The slurry is then stored in a storage tank and then sent to a casting system through a suitable delivery system, where it enters a "casting box" to be cast on a moving conveyor steel belt and then enters a dryer for drying. Summary of the Invention

[0006] There is a need for a method of obtaining an alternative material containing alkaloids that can be used in heat-not-burn products.

[0007] On the one hand, the present invention relates to a method for producing a sheet of a material containing alkaloids, the method comprising the steps of: providing a slurry comprising a material containing alkaloids, an aerosol-forming agent, and water; extruding the slurry. The method may further comprise the steps of: collecting the extruded slurry in a storage tank having an outlet, and providing a matrix sheet comprising fibers. The method may further comprise the step of: supplying the slurry from the outlet onto the matrix sheet to form a slurry strip, wherein the matrix sheet together with the slurry strip forms a sheet of the material containing alkaloids.

[0008] The present invention also relates to a system for producing more than one sheet of a material containing alkaloids, the system comprising: more than one reel of a matrix sheet comprising fibers. The system may further comprise means for supplying the slurry to more than one matrix sheet comprising fibers. The means may comprise: an extruder adapted to extrude the slurry; a storage tank adapted to receive the slurry and having a plurality of outlets; and a moving element adapted to move, along a conveying direction, more than one matrix sheet unwound from more than one reel under the outlets such that the slurry is applied to more than one matrix sheet.

[0009] The present invention also relates to a system for producing a sheet of material containing alkaloids, the system comprising: a reel of a matrix sheet comprising fibres; and a device for supplying a slurry to the matrix sheet comprising fibres. The device may comprise: an extruder adapted to extrude the slurry; a storage tank having an outlet adapted to receive the slurry from the extruder; and a moving element adapted to move, along a conveying direction, a matrix sheet comprising fibres unwound from the reel under the outlet such that the slurry is applied to the matrix sheet.

[0010] The slurry is supplied to the matrix sheet comprising fibres to form a sheet of material containing alkaloids. Thus, a "fibrous matrix" for the slurry already exists and it is not necessary to add a high amount of fibres to the slurry to obtain a sheet of material containing alkaloids with a relatively high tensile strength. This aspect may allow for less water to be used in the slurry and thus also less energy to be used in drying the resulting sheet of material containing alkaloids.

[0011] As used herein, the term "sheet" refers to a layered element having a width and length that are substantially greater than its thickness.

[0012] As used herein, the term "slurry" refers to a liquid, viscous or pasty material which may comprise an emulsion of different liquid, viscous or pasty materials. The slurry may contain a certain amount of solid particles provided that the slurry still exhibits liquid, viscous or pasty behaviour.

[0013] Hereinafter, the terms "upstream" or "downstream" are used to refer to the direction of flow of the slurry.

[0014] As used herein, the term "movable support" refers to any device comprising a surface adapted to move in at least one longitudinal direction. The movable support may form a closed loop so as to provide an uninterrupted conveying capacity in one direction. However, the movable support may also move in a reciprocating manner. The movable support may comprise a conveyor belt. The movable support may be substantially flat. The movable support may exhibit a structured or unstructured surface. The movable support may comprise a sheet-like movable and bendable belt. The belt may be made of a metallic material including, but not limited to, steel, copper, iron alloys and copper alloys, or rubber.

[0015] "Matrix sheet comprising fibres" refers to a sheet that serves as a matrix for the slurry and is formed of a material comprising fibres. The material forming the sheet may comprise any type of fibre, such as cellulose fibres. The sheet of material may be placed on top of the movable support or may be self-supporting.

[0016] "Material containing alkaloids" is a material containing one or more alkaloids. The alkaloids may include nicotine. Nicotine may be present, for example, in tobacco.

[0017] Alkaloids are a group of naturally occurring compounds that mainly contain basic nitrogen atoms. This group also includes some related compounds with neutral or even weakly acidic properties. Some synthetic compounds with similar structures are also called alkaloids. In addition to carbon, hydrogen, and nitrogen, alkaloids can also contain oxygen, sulfur, and, more rarely, other elements such as chlorine, bromine, and phosphorus.

[0018] Examples of alkaloids are caffeine, nicotine, theobromine, atropine, and tubocurarine.

[0019] As used herein, the term "homogenized tobacco material" refers to a material formed by coalescing particulate tobacco and containing the alkaloid nicotine. Thus, an alkaloid-containing material can be a homogenized tobacco material.

[0020] The most commonly used forms of homogenized tobacco material are reconstituted tobacco sheets and cast leaves. The process of forming a sheet of homogenized tobacco material generally includes the step of mixing tobacco powder and a binder to form a slurry. The slurry is then used to form a tobacco sheet. For example, so-called cast leaves are produced by casting a viscous slurry onto a moving metal belt. Alternatively, a slurry with low viscosity and high water content can be used to form reconstituted tobacco in a papermaking-like process.

[0021] The sheet material of tobacco can be referred to as reconstituted sheet material and is formed using particulate tobacco or a particulate tobacco blend, a humectant, and an aqueous solvent to form a tobacco composition.

[0022] In addition to tobacco, the homogenized tobacco sheet can include a binder. The binder can be guar gum. The homogenized tobacco sheet can also include an aerosol-forming agent. The aerosol-forming agent can be glycerol.

[0023] The term "aerosol-forming substrate" refers to a substrate that is capable of releasing volatile compounds that can form an aerosol. Generally, the aerosol-forming substrate releases volatile compounds upon heating. The aerosol-forming substrate can include a material containing alkaloids, which contains volatile alkaloid flavor compounds that are released from the aerosol-forming substrate upon heating. The aerosol-forming substrate can include a homogenized material. The aerosol-forming substrate can include a homogenized tobacco material.

[0024] As used herein, the term "aerosol-generating device" refers to a device that is configured to interact with an aerosol-forming substrate to generate an aerosol. Preferably, the aerosol-generating device includes an atomizer, such as a heater.

[0025] Thus, a sheet of material containing alkaloids is a sheet formed from a material containing any alkaloid or a combination of more than one alkaloid. The width of the sheet of material containing alkaloids is preferably greater than about 10 mm, more preferably greater than about 20 mm or about 30 mm. Even more preferably, the width of the sheet of material containing alkaloids is between about 60 mm and about 2500 mm. The thickness of the sheet of material containing alkaloids is preferably between about 50 μm and about 300 μm, more preferably, the thickness of the sheet is between about 100 μm and about 250 μm, and even more preferably between about 130 μm and 220 μm.

[0026] The sheet of material containing alkaloids can be used as an aerosol-forming substrate for an aerosol-generating device.

[0027] The slurry can include a variety of different components or ingredients. These components may affect the properties of the cast sheet of the material containing alkaloids. The first ingredient is a material containing alkaloids in, for example, powder form. Such a material can be, for example, a tobacco powder blend. Preferably, the tobacco powder blend contains most of the tobacco present in the slurry. In this way, the tobacco powder blend is the source of most of the tobacco in the homogenized tobacco material. Thus, the tobacco powder blend defines the taste of the final product (e.g., the aerosol produced by heating the homogenized tobacco material). Preferably, the amount of tobacco powder in the slurry is between about 20% and about 45% of the total mass of the slurry (i.e., the mass of the slurry including water). More preferably, the amount of tobacco powder in the slurry preferably ranges from about 25% to about 45% of the total mass of the slurry (i.e., the mass of the slurry including water).

[0028] Preferably, a binder is added to the slurry to enhance the tensile properties of the homogenized sheet. Preferably, an aerosol-forming agent is added to the slurry to facilitate the formation of an aerosol. Additionally, water can be added to the slurry to achieve a specific viscosity and humidity for casting the web of material containing alkaloids.

[0029] The amount of binder added to the slurry can be between about 0% and about 1% of the total mass of the slurry (i.e., the mass of the slurry including water). More preferably, the amount of binder added to the slurry ranges from about 0% to about 0.5%. The binder used in the slurry can be any of the gums or pectins described herein. The binder can ensure that the alkaloid powder remains substantially dispersed throughout the sheet of material containing alkaloids. Although any binder can be used, preferred binders are natural pectins (such as fruit, citrus or tobacco pectin), guar gums (such as hydroxyethyl guar gum and hydroxypropyl guar gum), locust bean gums (such as hydroxyethyl and hydroxypropyl locust bean gum), alginates, starches (such as modified or derivatized starches), celluloses (such as methyl, ethyl, ethylhydroxymethyl and carboxymethyl cellulose), tamarind gum, dextran, pullulan, konjac flour, xanthan gum, etc. A particularly preferred binder for use in the present invention is guar gum.

[0030] Suitable aerosol - forming agents included in the slurry for the sheet of alkaloid - containing material are known in the art and include, but are not limited to: monohydric alcohols such as menthol; polyhydric alcohols such as triethylene glycol, 1,3 - butanediol, and glycerol; esters of polyhydric alcohols such as glycerol monoacetate, glycerol diacetate, or glycerol triacetate; and aliphatic esters of mono -, di - or poly - carboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

[0031] Examples of preferred aerosol - forming agents are glycerol and propylene glycol.

[0032] The slurry may have an aerosol - forming agent content between about 1% and about 5% by mass of the total mass of the slurry (i.e., the slurry including water). Preferably, the aerosol - forming agent is between 1% and 3% of the total mass of the slurry, corresponding to an amount of aerosol - forming agent between about 2.9% and about 8.5% based on the dry weight of the slurry.

[0033] Water is also preferably present in the slurry. Preferably, the amount of water is between about 30% and 55% by mass of the total mass of the slurry (i.e., the mass of the slurry including water). More preferably, the amount of water is between about 45% and about 55% by mass of the total mass of the slurry (i.e., the mass of the slurry including water).

[0034] The alkaloid - containing material, preferably in powder form, may contain cellulose. However, preferably, no added cellulose fibers are present in the slurry, i.e., no additional fibers are added to the slurry other than the fibers already present in the alkaloid - containing material. Thus, the amount of fibers added to the slurry (i.e., other than those already present in the alkaloid - containing material) is preferably less than 0.5% by mass of the total mass of the slurry (i.e., the mass of the slurry including water). More preferably, the added fibers are present in an amount less than about 0.1% of the total mass of the slurry.

[0035] The slurry is formed at a given location. Then the slurry can be stored. The slurry can be stored and formed, for example, at the same location (e.g., in the same storage tank) or at two different locations (e.g., in two different storage tanks). The storage tanks used are preferably known in the art. In addition, the slurry can be formed or stored in a single storage tank or multiple storage tanks. Preferably, in the storage tank, there is a mixer to homogenize the slurry.

[0036] The slurry is transferred from the storage tank to the extruder. The slurry is introduced, for example, into the inlet of the extruder, extruded, and exits the extruder at the outlet of the extruder. The extruder can have more than one inlet and more than one outlet. The extruder can include a screw, and the rotation of the screw can cause compression of the slurry. Heating elements can be present in the extruder to heat the slurry. The rotation of the screw can also cause heating of the slurry. The extruder can include a single-screw extruder. Thus, the extrusion here can include compressing the slurry by means of the screw. Due to the compression, the slurry is directed towards the outlet of the extruder. The slurry after extrusion remains in the form of a slurry. Preferably, the extrusion step reduces the viscosity of the slurry.

[0037] In this context, the term "extrusion" is used in its general meaning, i.e., "to force or press out; to expel". The slurry after extrusion remains in the form of a slurry.

[0038] The extruded slurry is collected in a storage tank having an outlet. Preferably, the storage tank has a bottom wall, and the outlet is formed in the bottom wall. Preferably, the outlet includes an orifice formed in the bottom wall of the storage tank. The storage tank can be located below the extruder. The storage tank can be integral with the extruder.

[0039] Thus, there can be two configurations. In the first configuration, the slurry is introduced into a container. The container contains a screw that compresses the slurry towards the outlet. The container and the screw can be considered an extruder. The compressed slurry leaving the container is introduced into the storage tank. The slurry is supplied from the outlet of the storage tank or from multiple outlets of the storage tank to a substrate sheet or more than one substrate sheet.

[0040] In the second configuration, the screw is included in the storage tank. In other words, the storage tank is part of the extruder, and the screw is located inside the storage tank. The slurry is introduced into the storage tank. Then the slurry is compressed with the screw. The storage tank and the screw form an extruder. The compressed slurry leaves the storage tank from the outlet or multiple outlets of the storage tank. The slurry is supplied from the outlet of the storage tank to a substrate sheet or more than one substrate sheet.

[0041] In both configurations, the slurry is output from the outlet or multiple outlets of the storage tank.

[0042] Furthermore, a substrate sheet including fibers is provided. The substrate sheet defines a surface to which the slurry is supplied from the storage tank. The surface can be horizontal - i.e., parallel to the horizontal plane - or inclined. The surface can also be substantially vertical. The substrate sheet can be provided in an unwound roll.

[0043] The substrate sheet moves along the conveying direction.

[0044] Preferably, the storage tank including the outlet is positioned above the substrate sheet. More preferably, the outlet is located above the substrate sheet.

[0045] A substrate sheet including fibers is generally a relatively "strong" sheet, and its tensile strength enables it to be conveyed between rollers without any other substrate with which it must come into contact. The tensile strength of the substrate sheet is preferably between about 0.1 Newton / (millimeter) 2 and about 1 Newton / (millimeter) 2 .

[0046] The substrate sheet can be made of different natural or synthetic materials, including cellulose, jute, bamboo pulp, cotton, silk, or combinations thereof. The choice of material is made based on the expected mechanical properties of the final sheet including the alkaloid-containing material.

[0047] The fiber content in the substrate sheet is preferably less than 50 grams / (meter) 2 .

[0048] The cellulose fibers forming the sheet are preferably known in the art and include, but are not limited to: softwood fibers, hardwood fibers, jute fibers, flax fibers, tobacco fibers, and combinations thereof. In addition to pulping, the cellulose fibers can be subjected to suitable processes such as refining, mechanical pulping, chemical pulping, bleaching, sulfate pulping, and combinations thereof. The cellulose fibers can include tobacco stem material, stalks, or other tobacco plant materials. Preferably, the cellulose fibers (such as wood fibers) contain a low lignin content. Alternatively, the fibers (such as plant fibers) can be used together with the above fibers or in substitutes containing bamboo.

[0049] The substrate sheet including fibers includes fibers having an average fiber length preferably between about 0.7 millimeters and about 50 millimeters. More preferably, the average fiber length of the fibers in the substrate sheet containing fibers is between about 1 millimeter and about 25 millimeters. More preferably, the average fiber length of the fibers in the substrate sheet containing fibers is between about 1 millimeter and about 10 millimeters. More preferably, the average fiber length of the fibers in the substrate sheet containing fibers is between about 1 millimeter and about 5 millimeters. Even more preferably, the average fiber length of the fibers in the substrate sheet containing fibers is between about 1.2 millimeters and about 1.8 millimeters.

[0050] The average length of the fibers refers to their true length (whether they are curled or entangled), as measured by MORFI COMPACT commercialized by Techpap SAS. The average length is the mathematical average of the measured fiber lengths of N fibers measured by MORFI COMCPACT, where N > 5. MORFI COMPACT is a fiber analyzer that measures the length of the fibers after the fiber frame, thereby measuring the length they actually form. If the length of the measured object is between 200 microns and 10,000 microns and its width is between 5 microns and 75 microns, the measured object is considered a fiber. When deionized water is added to the fibers, the fiber length is measured using Morfi software.

[0051] The fibers in the matrix sheet can be woven or non-woven. If non-woven, the fibers can be oriented mainly in one direction. Also, the fibers can be randomly oriented, for example. If woven, various patterns can be used.

[0052] The matrix sheet defines a first surface and a second surface. For example, the first surface or the second surface can be a substantially flat surface. The first surface and the second surface can be opposite to each other. In order to apply or distribute the slurry present in the storage tank to the first surface of the matrix sheet, it is preferably to move the matrix sheet such that the slurry is applied to the first surface along its length, thereby forming a slurry strip on the matrix sheet including the fibers.

[0053] The slurry does not need to be applied to the entire first surface. The slurry can be applied only to a part of the first surface, for example, to the central part of the first surface.

[0054] Therefore, preferably, the matrix sheet moves along the conveying direction, for example, linearly, and a part of the first surface of the matrix sheet contacts the slurry.

[0055] The slurry in contact with the matrix sheet can be completely absorbed by the matrix sheet. The slurry can form a coating on the first surface of the matrix sheet. The slurry can also be partially absorbed by the matrix sheet and partially coat the first surface of the matrix sheet. The resulting sheet formed by the matrix sheet and the slurry can have different compositions in a cross-section taken perpendicular to the first surface of the matrix sheet. At the second surface, there can be a minimum amount of slurry. At the first surface, there can be a maximum amount of slurry. Between the first surface and the second surface, the combination of the material of the matrix sheet and the slurry can exist in different concentrations.

[0056] In order to move the matrix sheet along the conveying direction, a moving element can be provided. The moving element can include a movable support, and the matrix sheet including the fibers can be positioned on the movable support such that the movable support conveys the matrix sheet when moving.

[0057] In another embodiment, the moving element can include a moving roller that moves the matrix sheet in its rotation. The support sheet can be freely upright on a part of its length.

[0058] The amount of the slurry in the storage tank is preferably maintained substantially constant. For example, the amount of the slurry in the storage tank is equal to a predetermined amount. Preferably, the predetermined amount of the slurry in the storage tank is constantly maintained. For example, a predetermined level of the slurry in the storage tank is set. To obtain a substantially constant level of the slurry in the storage tank, when supplying the slurry onto the substrate sheet, the slurry is continuously supplied to the storage tank. The level of the slurry in the storage tank can be checked by a sensor, and the amount of the slurry supplied to the storage tank by the extruder can be changed to maintain a constant level in the storage tank.

[0059] As described above, from the outlet of the storage tank, the slurry is supplied onto the substrate sheet. The slurry forms a deposit on the first surface of the substrate sheet.

[0060] In addition, due to the movement of the substrate sheet in the conveying direction, the slurry supplied from the outlet forms a slurry strip. The combination of the substrate sheet and the slurry strip provided on its first surface forms a sheet of material containing alkaloids.

[0061] In addition to the substrate sheet and the slurry strip, other elements can also be combined to form a sheet of material containing alkaloids. The substrate sheet itself can be a multi-layer sheet. The substrate sheet can include a flavor sheet, a sheet of material including nicotine, etc.

[0062] To form a sheet of material containing alkaloids, the slurry is supplied onto a pre-formed substrate sheet including fibers, allowing the use of substantially additive-free fibers in the slurry. Fibers are usually added to the slurry to increase the tensile strength of the sheet and act as a reinforcing agent.

[0063] However, the presence of the substrate sheet onto which the slurry is supplied provides sufficient tensile strength for the resulting sheet of material containing alkaloids. The addition of cellulose fibers to the slurry can be avoided.

[0064] In the slurry with added fibers, a relatively large amount of water may be required in the slurry because fiber pulping requires water. Additionally, due to the large amount of water present in the slurry, a high amount of energy is required to dry the slurry and form a sheet of material containing alkaloids. In this "high water content" process, the conveyor steel belt on which the slurry is cast can also play an important role: any defects in the conveyor belt can be transferred to the cast sheet, so usually a high-quality belt is required. Removing fibers from the slurry allows for a reduction in the amount of water required to homogenize the slurry. A certain amount of water may still be required for good homogenization. This certain amount of water can then be further reduced by an extrusion process. This relatively "dense" slurry is suitable for application onto a substrate sheet including fibers.

[0065] Drying the sheet of material containing the alkaloids produced according to the present invention requires less drying time or drying power. Preferably, when the substrate sheet is wound in a reel, it is already dry. The substrate sheet can be wetted before contacting the slurry, for example by spraying water thereon. Wetting is to promote the penetration of the slurry into the substrate sheet. The resulting multi-layer sheet of material containing alkaloids or composite sheet of material containing alkaloids is only "partially wetted", and the drying time or the energy required for drying is relatively less. When used as an aerosol-forming substrate, the lower "intensity" of drying allows for better control of the odor of the aerosol produced by the sheet of material containing alkaloids. During drying, alkaloids, odors or other volatile substances can evaporate, and their concentration in the sheet of material containing alkaloids can be reduced. Minimizing drying when alkaloids are present helps to control the aerosol properties. Compared to the dryer used for casting leaves, a smaller dryer may be required. Energy can be saved. Floor space can be saved.

[0066] Preferably, the storage tank includes a plurality of outlets, and the step of supplying the slurry from the outlets includes the following steps: supplying the slurry from the plurality of outlets so as to form a plurality of slurry strips. Preferably, all the outlets of the plurality of outlets are formed on the bottom wall of the storage tank. Due to the plurality of outlets, more than a single slurry strip can be produced. A single substrate sheet including fibers can be provided, and the number of slurry strips supplied thereon is equal to the number of outlets formed on the storage tank. The single substrate sheet having a plurality of slurry strips on its surface can be cut into sub-sheets. Alternatively, a single slurry strip can be formed on the substrate sheet, and other slurry strips can be formed elsewhere. Thus, the substrate sheet can include one or more than one slurry strip. Preferably, the plurality of slurry strips are parallel to each other.

[0067] For example, if there is a movable support, a slurry strip can be formed on the substrate sheet, and a slurry strip can be formed on the movable support.

[0068] More preferably, the step of supplying the slurry from the plurality of outlets includes the following steps: supplying the slurry from the plurality of outlets onto more than one substrate sheet including fibers to form more than one sheet of material containing alkaloids. Preferably, more than one sheet of material containing alkaloids is formed simultaneously. More than one substrate sheet including fibers can be provided. The number of substrate sheets can be equal to or different from the number of outlets formed in the storage tank. Thus, in each substrate sheet, a single slurry strip, or more than one slurry strip, or no slurry strip can be formed. If the number of substrate sheets is equal to the number of outlets formed in the storage tank, a single slurry strip can be formed. If the number of substrate sheets is lower than the number of outlets, more than one slurry strip can be formed. The cutting step of cutting a "wide" sheet of material containing alkaloids into narrower sheets can be avoided. The process requires fewer components, such as cutting blades. Machines such as dryers can be smaller.

[0069] In addition, in the case where the number of substrate sheets is equal to the number of outlets in the storage tank, the substrate sheets can be positioned such that slurry is not supplied to some of the substrate sheets, while more than one slurry strip is formed on other substrate sheets.

[0070] In the case of more than one substrate sheet, the substrate sheets can be identical to each other. In particular, the substrate sheets can all have the same thickness. The substrate sheets can all have the same width.

[0071] Preferably, the thickness of the substrate sheet is between about 175 microns and about 250 microns. More preferably, the thickness of the substrate sheet is between about 190 microns and about 220 microns. Preferably, the width of the substrate sheet is between 100 millimeters and 150 millimeters.

[0072] Preferably, the step of supplying slurry from a plurality of outlets includes spraying the slurry onto the substrate sheet. Preferably, the step of supplying slurry from a plurality of outlets includes spraying the slurry onto at least one of the substrate sheets among more than one substrate sheet. Preferably, the step of supplying slurry from a plurality of outlets includes spraying the slurry onto all of the substrate sheets among more than one substrate sheet. Preferably, the nozzle sprays the slurry from the storage tank onto the substrate sheet, preferably onto the surface of the substrate sheet including fibers, preferably onto the surfaces of more than one substrate sheet. The slurry present in the storage tank can be highly viscous, for example, it can have a dynamic viscosity between about 18,000 centipoise and about 45,000 centipoise. For this reason, preferably one or more pumps are provided to push the slurry towards the outlets of the storage tank. Preferably, the nozzle is positioned at each outlet.

[0073] Preferably, the step of supplying slurry from a plurality of outlets includes depositing the slurry on the substrate sheet. Preferably, the step of supplying slurry from a plurality of outlets includes depositing the slurry on at least one of the substrate sheets among more than one substrate sheet. Preferably, the step of supplying slurry from a plurality of outlets includes depositing the slurry on all of the substrate sheets among more than one substrate sheet. The supply of slurry onto the substrate sheet can be by gravity only. A roller can be positioned at each outlet. The roller can be in contact with the substrate sheet including fibers. The slurry falls from the storage tank to the outlet and then falls onto the roller by gravity. In this way, the roller coats the substrate sheet or more than one substrate sheet with the slurry.

[0074] Preferably, the method comprises the steps of: adjusting the pressure or flow rate of the slurry supplied from the outlet. Preferably, the method comprises the steps of: adjusting the pressure or flow rate of the slurry supplied from at least one of a plurality of outlets. Preferably, the method comprises the steps of: adjusting the pressure or flow rate of the slurry supplied from all of the plurality of outlets. Even more preferably, the step of adjusting the pressure or flow rate of the slurry supplied from the outlet comprises: adjusting the pressure or flow rate of the slurry supplied from at least one of the plurality of outlets independently of at least one of the other outlets of the plurality of outlets. Given N outlets, and selecting one outlet out of the available N, the pressure or flow rate of the slurry leaving the selected outlet is independent of at least one of the pressure or flow rate of the slurry leaving the other N - 1 outlets. Preferably, the pressure or flow rate of the slurry is adjusted independently at all of the plurality of outlets. Preferably, at least one of the plurality of outlets comprises a pump to adjust the pressure or flow rate of the slurry leaving the outlet. More preferably, each of the plurality of outlets comprises a pump for adjusting the pressure or flow rate of the slurry leaving the outlet. Preferably, both the pressure and the flow rate can be adjusted independently at each outlet from at least another outlet of the plurality of outlets.

[0075] Preferably, the method comprises the step of reducing the amount of water in the slurry during extrusion. Preferably, the method comprises the steps of: reducing the amount of water in the slurry while compressing the slurry with a screw. During the extrusion process, the amount of water in the slurry can be reduced. This is attributed to, for example, the heat and pressure present during the extrusion process. Reducing the water in the slurry can allow for a denser slurry to be obtained, which requires less time and energy to dry when supplied to the substrate sheet. In this way, control over the resulting odor and alkaloid concentration in the resulting sheet of the alkaloid-containing material can be obtained. Preferably, the amount of water removed during extrusion is less than about 50% of the total mass of the slurry. Preferably, the amount of water removed during extrusion is less than about 25% of the total mass of the slurry. Preferably, the amount of water removed during extrusion is less than about 15% of the total mass of the slurry. Preferably, the amount of water removed during extrusion is greater than about 2% of the total mass of the slurry. More preferably, the amount of water removed during extrusion is greater than about 4% of the total mass of the slurry.

[0076] After extrusion, the amount (by weight) of the binder remains substantially the same as before extrusion. After extrusion, the amount (by weight) of the aerosol former remains the same as before extrusion. After extrusion, the amount (by weight) of the alkaloid-containing material remains the same as before extrusion. Preferably, after extrusion, the amount of water is reduced from about 30% to about 55% of the total mass of the slurry before extrusion to about 30% to 50% of the total mass of the slurry.

[0077] Preferably, the method includes the following steps: orienting the slurry flow supplied from one or more of the plurality of outlets with a component along the moving direction of the substrate sheet. Preferably, the outlet of the storage tank has a specific shape. At least one of the plurality of outlets may include a tube or nozzle having a curvature. For example, the tube or nozzle may have an arched configuration. Preferably, a curved nozzle is provided. This curvature is adapted to impart a component with a non-zero axis along a direction parallel to the conveying direction of the substrate sheet to the slurry flow flowing out of the pipe or nozzle.

[0078] Preferably, the method includes the step of evaluating the thickness of a sheet of material containing alkaloids. Preferably, the method includes the step of evaluating the thickness of at least one sheet of material of more than one sheet of material containing alkaloids. Preferably, the method includes the step of evaluating the thickness of all sheets of material of more than one sheet of material containing alkaloids. Preferably, the method includes the step of compressing a sheet of material containing alkaloids. Preferably, the method includes the step of compressing at least one sheet of material of more than one sheet of material containing alkaloids. Preferably, the method includes the step of compressing all sheets of material of more than one sheet of material containing alkaloids. More preferably, the method includes the step of changing the thickness of a sheet of material containing alkaloids by compressing the sheet of material containing alkaloids. More preferably, the method includes the step of changing the thickness of a sheet of material containing alkaloids by compressing at least one sheet of material of more than one sheet of material containing alkaloids. More preferably, the method includes the step of changing the thickness of a sheet of material containing alkaloids by compressing all sheets of material of more than one sheet of material containing alkaloids. The compressing step may include a calendering step. The compressing step can be performed by inserting a sheet of material containing alkaloids between two compression rollers. The thickness of the sheet can be checked after the slurry has been deposited and dried. The thickness of the sheet can be measured by an optical sensor. Suitable optical sensors may include an X-ray sensor or a laser sensor or a combination thereof. If the measured thickness is outside the desired range, a feedback loop can be provided to correct the thickness of the sheet.

[0079] Preferably, the step of providing a slurry comprising a material containing alkaloids, an aerosol former, and water includes at least one of the following: providing the material containing alkaloids to the slurry in an amount between about 40% and about 70% by weight of the total weight of the slurry; providing water to the slurry in an amount between about 30% and about 55% by weight of the total weight of the slurry; providing a binder to the slurry in an amount between about 0% and about 1% by weight of the total weight of the slurry; or providing an aerosol former to the slurry in an amount between 1% and about 5% by weight of the total weight of the slurry.

[0080] More preferably, the step of providing the material containing alkaloids to the slurry includes providing the material containing alkaloids to the slurry in an amount between about 40% and about 50% by weight of the total weight of the slurry.

[0081] More preferably, the step of providing water to the slurry comprises providing water to the slurry in an amount between about 45% and about 55% of the total weight of the slurry. Since the amount of water in the material sheet containing alkaloids is relatively small, a relatively low drying time is required compared to the cast sheet. Minimal volatilization loss of the sheet can be achieved.

[0082] More preferably, the step of providing a binder to the slurry comprises providing a binder to the slurry in an amount between about 0% and about 0.5% of the total weight of the slurry. The amount of binder can depend on the desired properties of the material sheet containing alkaloids. If it is desired that the slurry be substantially absorbed by the substrate sheet, less binder can be used to improve absorption. If a slurry coating on the substrate sheet is preferred, a higher amount of binder can be used. The amount of binder can change the viscosity of the slurry. A higher amount of binder can result in a higher viscosity of the slurry.

[0083] More preferably, the step of providing an aerosol former to the slurry comprises providing an aerosol former to the slurry in an amount between 1% and about 3% of the total weight of the slurry.

[0084] Preferably, the step of providing a slurry comprising a material containing alkaloids, an aerosol former, and water comprises the step of grinding the material containing alkaloids into a powder having a size between about 8 microns and 200 microns. More preferably, the step of providing a slurry comprising a material containing alkaloids, an aerosol former, and water comprises the step of grinding the material containing alkaloids into a powder having a size between about 10 microns and 150 microns. Even more preferably, the step of providing a slurry comprising a material containing alkaloids, an aerosol former, and water comprises the step of grinding the material containing alkaloids into a powder having a size between about 15 microns and 120 microns. Since the slurry contains no or an extremely small amount of cellulose fibers other than the cellulose fibers already contained in the material containing alkaloids, the size of the powder does not need to be "extremely small". In order to obtain a uniform slurry, the particles of the material containing alkaloids are preferably "small". The small size is also due to the absence of added fibers, which act as "glue" in the cast leaf. Preferably, the size of the ground particles of the material containing alkaloids is less than 200 microns, preferably less than 180 microns, preferably less than 160 microns, preferably less than 140 microns, preferably less than 120 microns, preferably less than 100 microns, preferably less than 80 microns, preferably less than 60 microns, preferably less than 40 microns. Preferably, the size of the ground particles of the material containing alkaloids is greater than 8 microns, preferably greater than 12 microns, preferably greater than 20 microns, preferably greater than 30 microns, preferably greater than 50 microns, preferably greater than 70 microns.

[0085] For the size of the particles of the material containing alkaloids, it means the Dv95 size. Each of the values listed above indicates the Dv95 of the particle size. The "v" in Dv95 indicates considering the volume distribution. Using the volume distribution introduces the concept of an equivalent sphere. An equivalent sphere is a sphere that is equal to the real particles in the property we are measuring. Thus, for the light scattering method, it is a sphere that will produce the same scattering intensity as the real particles. This is basically a sphere of particles with the same volume. In addition, the "95" in Dv95 means that 95% of the distribution has a smaller particle size and 5% has a larger particle size in terms of diameter. Therefore, the particle size is the size according to the volume distribution, where 95% of the particles have a diameter smaller than the said value (the diameter of the corresponding sphere of particles with substantially the same volume). A particle size of 60 microns means that 95% of the particles have a diameter smaller than 60 microns, where the diameter is the diameter of the sphere having the volume corresponding to the particles.

[0086] The Dv95 size of the particles is measured using a Horiba LA 950 or LA 960 particle size distribution analyzer. The HORIBA LA-960 particle size analyzer measures the particle size distribution using the laser diffraction method. This technique uses first principles to calculate the size using the light scattered (edge diffraction) from the particles and passing through the particles (secondary scattering refraction). The LA-960 incorporates the Mie scattering theory.

[0087] In addition, the viscosity of the slurry can depend on the size of the powder of the material containing alkaloids. The larger the size, the more viscous the slurry becomes.

[0088] Preferably, the method includes the steps of: providing a matrix sheet having fibers with an average fiber length between about 0.7 mm and about 50 mm. Preferably, the method includes the steps of: providing at least one matrix sheet out of more than one matrix sheet having fibers with an average fiber length between about 0.7 mm and about 50 mm. Preferably, the method includes the steps of: providing more than one matrix sheet all having fibers with an average fiber length between about 0.7 mm and about 50 mm. More preferably, the average fiber length of the fibers of the matrix sheet containing fibers is between about 1 mm and about 25 mm. More preferably, the average fiber length of the fibers of the matrix sheet containing fibers is between about 1 mm and about 10 mm. More preferably, the average fiber length of the fibers of the matrix sheet containing fibers is between about 1 mm and about 5 mm. Even more preferably, the average fiber length of the fibers of the matrix sheet containing fibers is between about 1.2 mm and about 1.8 mm.

[0089] Preferably, the matrix sheet is a woven sheet. A woven sheet is a sheet in which the fibers are entangled together. Not all fibers need to be entangled, but a part of them are. A woven sheet allows for obtaining uniform and relatively high mechanical strength.

[0090] Preferably, the steps of extruding the slurry and collecting the extruded slurry in a storage tank having a plurality of outlets include: extruding the slurry by means of a screw. Preferably, the extrusion of the slurry is carried out in a single-screw extruder. The single-screw extrusion generates pressure in the slurry. This forces the slurry to be extruded. The single-screw extruder can be used as part of a large extrusion system or as an independent extruder. The screw can be located within a heated barrel. When the screw rotates, it moves the slurry within the heated barrel. In this way, the slurry reaches the desired temperature and is thoroughly mixed to form a uniform slurry. Then, the pressure accumulated by the single-screw extruder compresses the slurry of the extruder. The extrusion includes compressing the slurry by means of the screw. More preferably, the extrusion step includes the step of inserting the slurry into the single-screw extruder. Although the slurry exits at the outlet of the extruder, the process is still considered an extrusion. The storage tank can be part of the extruder or outside the extruder.

[0091] Preferably, the method includes the step of homogenizing the extruded slurry collected in the storage tank. The slurry flowing out of the extruder enters the storage tank. Alternatively, the storage tank is part of the extruder, and the extruded slurry is collected in a part of the storage tank where it is extruded. In the storage tank, the slurry is preferably mixed or otherwise agitated. The agitation or mixing can improve the uniformity of the slurry. Preferably, the structure or composition of the slurry is always uniform. Thus, the composition of the slurry and its properties, such as viscosity and temperature, are the same throughout the storage tank. In this way, the slurry supplied from the plurality of outlets is substantially the same at each outlet. If more than one sheet of alkaloid-containing material is formed by the method of the present invention, all the sheets will have substantially the same properties because the slurry output from the outlets has the same properties (assuming the use of a plurality of identical matrix sheets).

[0092] Preferably, the step of supplying the slurry from a plurality of outlets to form a plurality of parallel slurry strips includes: providing a moving roller located below the plurality of outlets; unwinding one or more reels to obtain one or more matrix sheets including fibers; placing the one or more matrix sheets including fibers onto the moving roller to move the one or more matrix sheets along the moving direction; and supplying the slurry from the plurality of outlets onto the one or more matrix sheets including fibers while the moving roller moves the one or more matrix sheets including fibers along the moving direction. Preferably, the step of supplying the slurry from a plurality of outlets to form a plurality of parallel slurry strips includes: providing a moving roller located below the plurality of outlets; unwinding more than one reel to obtain more than one matrix sheet including fibers; placing the more than one matrix sheet including fibers onto the moving roller to move the more than one matrix sheet along the moving direction; and supplying the slurry from the plurality of outlets onto the more than one matrix sheet including fibers while the moving roller moves the more than one matrix sheet including fibers along the moving direction.

[0093] Preferably, one or more substrate sheets are self - supporting. The rotation of the moving roller in turn moves one or more substrate sheets. Once moved, no conveyor belt is needed to support the substrate sheets. One or more substrate sheets including fibers can be "self - supporting". Preferably, the second surface of one or more substrate sheets opposite the first surface facing the outlet of the storage tank is not in contact with any other element at least over a certain length interval. The substrate sheets can travel "freely upright" after being supplied with the slurry, with neither surface in contact with any other element. There is substantially no longer a need for a conveyor belt to support the sheet of material containing alkaloids, which allows for greater flexibility in the overall system. In the process of casting the slurry onto a conveyor belt, a conveyor belt with strict dimensional requirements is usually required. When using self - supporting substrate sheets, such a belt may no longer be needed. BRIEF DESCRIPTION OF THE DRAWINGS

[0094] Specific embodiments will be further described only by way of example with reference to the accompanying drawings, in which:

[0095] - Figure 1 a schematic perspective view of an apparatus for producing a sheet of material containing alkaloids according to the present invention is shown;

[0096] - Figure 2 shows Figure 1 a front view of the apparatus;

[0097] - Figure 3 shows Figure 1 and Figure 2 a side view of the apparatus; and

[0098] - Figure 4 shows Figures 1-3 an enlarged view of details of the apparatus. DETAILED DESCRIPTION

[0099] First, referring to Figure 1 and Figure 2 , an apparatus for producing a sheet of material 200 containing alkaloids according to the present invention is designated and indicated by the reference numeral 100.

[0100] Preferably, the apparatus 100 is adapted to produce a plurality of sheets of material 200 containing alkaloids. In this embodiment, the plurality of sheets are sheets of homogenized tobacco material.

[0101] The apparatus 100 for producing sheets of homogenized tobacco material includes an extruder 2, a storage tank 3 located at the outlet 20 of the extruder 2, and a moving roller 4 located below the storage tank 3.

[0102] The extruder 2 includes: an inlet 21, into which a slurry 22 is introduced (by Figure 1The arrow in indicates to form a sheet of homogenized tobacco material; the screw 23 for extruding the slurry; and the outlet 20. The slurry 22 is pushed by the screw 23 from the inlet to the outlet 20 (see the arrow 22 again). The screw 23 for pushing the slurry 22 can be rotated by the motor 24 (see, for example, Figure 2 ).

[0103] The slurry 22 reaches the extruder 2 from different storage tanks or silos not shown in the drawings. The slurry 22 includes tobacco powder, water, a binder, and an aerosol former. Preferably, the binder is guar gum. Preferably, the aerosol former is glycerol. Preferably, no additional fibers are added to the slurry.

[0104] The slurry 22 at the inlet has the following composition by total mass

[0105] Water: 30% - 55%

[0106] Tobacco powder: 40% - 70%

[0107] Binder: 0% - 1%

[0108] Aerosol former: 1% - 5%

[0109] Added fibers: less than 0.5%

[0110] The slurry 22 reaches the storage tank 3 from the extruder 2. From the above composition, 5% of the water is removed from the slurry by the extrusion process.

[0111] The storage tank 3 includes a plurality of outlets all indicated by 30. The storage tank 3 can have any geometry, and in the depicted embodiment, it is substantially basin-shaped. The storage tank 3 includes a side wall 32 and also includes a bottom wall 33. A mixer 34 (indicated by the arrow in Figure 1 ) can be present inside the storage tank 3 to stir and mix the slurry.

[0112] In addition, a sensor 50 is present in the storage tank 3 to measure the vertical level of the slurry. Preferably, there is a feedback between the sensor 30 and the extruder 2 such that the slurry is maintained at a substantially constant level in the storage tank 3.

[0113] The moving roller 4 is located below the outlet 30. The moving roller 4 is adapted to rotate about its axis 6 in the rotational direction 5 indicated by the arrows in Figure 1 and 2 . The moving roller 4 defines an outer cylindrical surface 41.

[0114] In addition, the apparatus 100 includes a plurality of reels 7. Each of the plurality of reels 7 is made of a coil of a substrate sheet 8, such as a cellulose fiber sheet. The reels are unwound, and the free portion of the sheet 8 unwound from the reel 7 is positioned in contact with the moving drum 4. The substrate sheet 8 includes a first surface 11 and a second surface 1 that face each other. The second surface 1 preferably contacts the cylindrical surface 41 of the moving drum 4. The first surface 11 faces at least one of the plurality of outlets 30. The rotation of the moving drum 4 causes the plurality of substrate sheets 8 to move along a common transport direction, indicated by an arrow 12 in Figure 1 and 3 . Thus, the reels 7 are continuously unwound by the rotation of the drum 4.

[0115] Each of the plurality of substrate sheets 8 contacts the surface 41 of the moving drum 4 and, downstream of the drum 4 along the transport direction, is free-standing, i.e., neither the first surface 11 nor the second surface 1 is supported by any element. Another drum or roller (not visible in the drawing) may further pull up the plurality of sheets 8 in the transport direction 12.

[0116] The slurry 22 is supplied to the plurality of substrate sheets 8 from the outlets 30. Preferably, each of the plurality of outlets 8 supplies the slurry 22 to a single substrate sheet 8 of the plurality of sheets, as visible in Figure 2 . The slurry is delivered from the outlet 30 by gravity or by applying pressure (e.g., by a pump 31). By the pump 31, the slurry in the storage tank 3 is transferred from the storage tank 3 to the substrate sheet 8 through the plurality of outlets 30. Preferably, the pump 31 includes a flow rate controller (also not visible in the drawing) to control the amount of slurry transferred to the substrate sheet 8.

[0117] When the substrate sheet is supplied together with the slurry 22, the substrate sheet becomes a homogenized tobacco sheet 200. The slurry may be partially or completely absorbed by the substrate sheet 8. Most of the slurry may coat the substrate sheet 8, particularly the second surface 11.

[0118] In an embodiment, a plurality of orifices 35 are formed in the bottom wall 33 of the storage tank 3, each orifice being connected to a pipe 36 (see Figure 2 and Figure 3 ). A valve 37 regulates the flow rate of the slurry through the pipe 36. Downstream of the valve 37, in the flow direction of the slurry, the pipe 36 terminates in the outlet 30.

[0119] In a different embodiment (not shown), a plurality of orifices are formed directly in the bottom wall 16, and a plurality of pipes are connected, each pipe being connected to a different orifice, and no valve is present.

[0120] Each pipe 37 terminates at a nozzle 38, in which there is an outlet 30, as in Figure 3 and Figure 4As can be seen, nozzle 38 is a bent nozzle having a horizontal inlet 39 and an outlet 30 from which the slurry exits, thereby forming a flow having a component along the conveying direction 12.

[0121] As Figure 2 As better seen therein, the number of substrate sheets 8 is equal to the number of outlets 30. All the substrate sheets are in contact with the surface 41 of the drum 4 at their second surface 1. The width 42 of each substrate sheet 8 is preferably equal to the width of a standard "small reel" for further processing of the sheet 200 (e.g., preferably between about 10 mm and about 300 mm). The widths 42 of all the substrate sheets 8 are preferably the same.

[0122] Furthermore, preferably, additional sensors (not shown) are arranged at the substrate sheet 200 downstream of the outlet 30 to measure the weight per square centimeter and the thickness of the homogenized tobacco sheet 200. The sensors can be, for example, nuclear measurement heads. Additional sensors not shown in the figure are also preferably present, such as sensors for locating and determining the position of defects in the homogenized tobacco sheet, sensors for determining the moisture content of the sheet 200, sensors for measuring the thickness of the sheet, and sensors for checking the alignment of the sheet in order to avoid misalignment and jamming of the sheet in the case of forming more than one sheet.

[0123] The function of the apparatus 100 for forming a plurality of homogenized tobacco sheets 200 is as follows. A slurry 22 preferably formed by mixing and combining tobacco powder, water and other ingredients (preferably without added fibers or with a low content of added fibers) is transferred from a storage tank (not shown) to the extruder 2 using, for example, a line mixer (also not shown). At the extruder 2, the slurry reduces its water content and is extruded inside the storage tank 3. In the storage tank 3, the valve 36 is opened, with or without the need for a pump 31, and the slurry reaches the outlet 30. The nozzle 38 supplies the slurry onto the substrate sheet 8 which comprises fibers positioned to contact the moving drum 4. The movement of the drum 4 causes the substrate sheet 8 to be displaced along the conveying direction 12. Each nozzle 38 deposits the slurry on a different substrate sheet 8. Thus, a plurality of homogenized tobacco sheets 200 are formed.

[0124] The thickness and grammage of the sheet 200 controlled by the nuclear gauge are continuously monitored and feedback-controlled with a slurry measuring device immediately after the slurry supply.

Claims

1. A method for producing a sheet of material containing alkaloids, the method comprising the steps of: o providing a slurry comprising a material containing alkaloids, an aerosol former, and water; o extruding the slurry; o collecting the extruded slurry in a storage tank having a plurality of outlets; o providing more than one fibrous matrix sheet; o supplying the slurry from the plurality of outlets to form a plurality of slurry strips on the more than one fibrous matrix sheet to form more than one sheet of material containing alkaloids.

2. The method according to claim 1, wherein the step of supplying the slurry from the plurality of outlets comprises: o spraying the slurry onto at least one matrix sheet, or o depositing the slurry onto at least one matrix sheet.

3. The method according to claim 1 or 2, which comprises the following steps: o adjusting the pressure or flow rate of the slurry supplied from at least one of the plurality of outlets.

4. The method according to claim 3, wherein the step of adjusting the pressure or flow rate of the slurry supplied from at least one of the plurality of outlets comprises adjusting the pressure or flow rate of the slurry supplied from at least one of the plurality of outlets independently of at least one of the other outlets of the plurality of outlets.

5. The method according to claim 1 or 2, which comprises the following steps: o reducing the amount of water in the slurry while extruding.

6. The method according to claim 1 or 2, which comprises the following steps: o orienting the slurry flow supplied from at least one of the plurality of outlets with a component along the direction of movement of the matrix sheet.

7. The method according to claim 1 or 2, which comprises the following steps: o evaluating the thickness of at least one of the more than one sheets of material containing alkaloids; and o changing the thickness of at least one of the more than one sheets of material containing alkaloids by compressing at least one of the more than one sheets of material containing alkaloids when the evaluated thickness exceeds a given value range.

8. The method according to claim 1 or 2, wherein providing a slurry comprising a material containing alkaloids, an aerosol former, and water comprises at least one of the following: o providing the material containing alkaloids to the slurry in an amount between 40% and 70% of the total weight of the slurry; o providing water to the slurry in an amount between 30% and 55% of the total weight of the slurry; o providing a binder to the slurry in an amount between 0% and 1% of the total weight of the slurry; or o providing the aerosol former to the slurry in an amount between 1% and 5% of the total weight of the slurry.

9. The method according to claim 1 or 2, wherein the step of providing a slurry comprising a material containing alkaloids, an aerosol former, and water comprises the following steps: o grinding the material containing alkaloids into a powder having a size between 8 microns and 200 microns.

10. The method according to claim 1 or 2, which comprises the following steps: Provide at least one matrix sheet of more than one matrix sheet comprising fibers having an average fiber length between 0.7 mm and 2.5 mm.

11. The method according to claim 1 or 2, wherein comprises the following steps: o Homogenize the extruded slurry collected in the storage tank.

12. The method according to claim 1 or 2, wherein the slurry is supplied from the plurality of outlets to form a plurality of parallel slurry strips comprises: o Provide a moving roller located below the plurality of outlets, the moving roller rotating about an axis; o Provide a plurality of reels of matrix sheets; o Unwind the plurality of reels to obtain more than one matrix sheet comprising fibers; o Place the more than one matrix sheet comprising fibers in contact with the moving roller so that the more than one matrix sheet moves in the moving direction due to the rotation of the moving roller; o Supply the slurry from the plurality of outlets onto the more than one matrix sheet comprising fibers while the more than one matrix sheet comprising fibers is moved in the moving direction by the moving roller.

13. A system for producing more than one sheet of material containing alkaloids, the system comprises: – A plurality of reels of matrix sheets comprising fibers; – Equipment for supplying slurry to more than one matrix sheet comprising fibers, the equipment comprising: i. An extruder adapted to extrude slurry; ii. A storage tank adapted to hold the slurry, the storage tank having a plurality of outlets; and iii. A moving element adapted to move the more than one matrix sheet comprising fibers unwound from the plurality of reels below the outlets in a conveying direction such that the slurry is applied to the more than one matrix sheet comprising fibers.

14. The system according to claim 13, wherein the extruder is a screw extruder.

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