Method for manufacturing plant source reconstructed material layer

Abstract

A method of manufacturing a layer of plant-derived reconstituted material comprises the steps of providing a starting material (M1) consisting of solid components at a first temperature, dry milling the solid components of the starting product (M1) to obtain a dry powder product (M2). The dry powder product (M2) is then mixed with one or more mixed liquids (L) having a second temperature greater than the first temperature, thereby obtaining a mixture (I) having a third temperature greater than or equal to the enzyme inactivation temperature of the starting material (M1). The mixing step is carried out in such a way that the third temperature is reached within a time interval shorter than the predetermined time interval. The mixture (I) is then transferred in the form of a continuous layer (S1) onto a conveyor belt (300) and dried, thereby obtaining a dried continuous layer (S2).

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a web of reconstituted material of plant origin, in particular for use in the manufacture of conventional or heat-not-burn (HNB) smoking articles. In particular, the method is applied to materials other than tobacco. Background Art

[0002] It is known in the art to produce reconstituted tobacco rolling materials starting from a high-flowability tobacco mixture ("slurry") having a very fine particle size.

[0003] The application of this method to plant materials other than tobacco has proven to be very complicated and less satisfactory, since these materials, although inexpensive to use, contain substances which are susceptible to chemical and physical changes during processing, in particular during heating, with the consequence that unpleasant odors and the undesirable generation of unpleasant flavors occur when consuming the corresponding smoking articles made therefrom. Summary of the invention

[0004] Therefore, the technical purpose of the present invention is to provide a method for manufacturing coils of plant-derived recycled materials without the disadvantages of the prior art.

[0005] In particular, the object of the present invention is to provide a method for manufacturing coils of reconstituted material of plant origin which allows its application on materials other than tobacco, in order to obtain a product of a quality suitable for sale.

[0006] Another object of the present invention is to provide a method for manufacturing a plant-derived recycled material roll, wherein the plant structure required for implementing the method is simple.

[0007] The indicated object is substantially achieved by a method according to the features of claim 1 and / or one or more of the claims dependent thereon.

[0008] BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Further features and advantages of the present invention will become more apparent from the following non-limiting description of a preferred but non-exclusive exemplary embodiment of a method for manufacturing a tobacco coil, as follows: Figure 1 , which shows a schematic diagram of an exemplary (and therefore non-limiting) embodiment of a plant for implementing the method of the invention. DETAILED DESCRIPTION

[0010] Now refer to Figure 1 An embodiment of the method of the present invention is described with reference to the corresponding equipment marked as 1 for implementing the method of the present invention.

[0011] According to the invention, the method comprises the following steps: providing a first amount of starting material "M1" consisting of solid components, in particular at least partly, preferably entirely, a plant fiber product different from tobacco.

[0012] According to a first example, the starting material "M1" is rapeseed.

[0013] According to a second example, the starting material "M1" is hay. The term "hay" refers to a plant collection comprising cut and dried grasses and fodder plants. In addition, the term "grass" (or herbaceous plant) refers generally to plants with non-woody stems that are usually grown in the wild or planted in fields.

[0014] According to a third example, the starting material "M1" is straw. The term "straw" refers to a plant collection comprising the stalks of cereal plants (such as wheat, oats, rice or barley) which are separated from the cereals after harvesting, cutting and drying.

[0015] However, it should be noted that the same method according to the invention can be implemented starting from common plant fiber products other than tobacco and substitutes for rapeseed, such as natural fibers, such as cellulose fibers.

[0016] Furthermore, it is also possible that the starting material is formed from a mixture of plant fiber products other than tobacco.

[0017] The first amount of starting material "M1" is processed while it is at a first supply temperature. The first temperature is below the enzyme activation temperature of the starting material "M1" used in the device and is preferably equal to the ambient temperature.

[0018] In the present description, "enzyme activation temperature" refers to the lower limit of the temperature range in which the enzyme is activated and develops. Enzyme activation is a (known) phenomenon that leads to oxidation and deterioration of the fats and oils naturally contained in the starting material "M1" itself. In fact, such enzymes lead to the formation of various types of compounds characterized by unpleasant odors and tastes, which leads to a decrease in the organoleptic properties of the material.

[0019] This temperature range is an intrinsic characteristic of the starting material "M1" used.

[0020] For rapeseed, the above temperature range is usually between 30° C. and 63° C. Therefore, for rapeseed, the enzyme activation temperature can be set at about 30° C., above which the enzyme in the oil naturally contained in the starting material "M1" begins to work.

[0021] For hay, the above temperature range is usually between 33° C. and 60° C. Therefore, for hay, the enzyme activation temperature can be set at about 33° C., above which the enzymes in the oil naturally contained in the starting material "M1" begin to work.

[0022] For rapeseed between 35°C and 68°C. Thus, for rapeseed, the enzyme activation temperature can be set at about 35°C, above which the enzymes in the oil naturally contained in the starting material "M1" begin to function. Advantageously, keeping the first temperature below the enzyme activation temperature ensures that the starting material "M1" is substantially free of such enzymes.

[0023] Then, the method comprises a step of grinding the solid components of the starting material "M1" to dry grind to obtain a dry powder product "M2" having a first particle size, preferably between 20 microns and 500 microns, more preferably between 70 microns and 250 microns. In other words, the solid particles of the dry powder product "M2" obtained by this method have a wide range of particle size values, but include particles with a maximum particle size of at most 500 microns, preferably at most 250 microns.

[0024] The term "particle size" refers to the diameter of the particle itself. In addition, it should be understood that the particle size of substantially all particles is within the above range.

[0025] like Figure 1 As shown, for this purpose, the apparatus 1 comprises a grinding device 100 of the silo type, hammer mill type or pin mill type, which is specially equipped with a screen or other screening device configured to allow only particles smaller than a predetermined size to pass through.

[0026] The grinding unit 100 may be defined by a single stage or multiple stages.

[0027] The grinding step is followed by a mixing step in which the particles of the dry powder product "M2" are combined and mixed with a second amount of one or more liquids "L" to obtain a mixture "I".

[0028] The one or more liquids "L" have a second temperature higher than the first supply temperature, thereby increasing the temperature of the mixture while increasing the liquid component content.

[0029] For example, the one or more liquids "L" may be water and / or at least one binding agent (eg a cellulose-based binding agent) and / or an aerosol-forming material and / or a fragrance.

[0030] The mixing step is performed by a mixer 200 of known construction connected to at least one feeder 210 for adding liquid components.

[0031] Preferably, the mixer 200 is configured to handle different amounts of products. In other words, the mixer 200 is configured to supply discrete amounts of mixture "I", each batch of mixture "I" coming from a corresponding loading cycle of a first amount of dry powder product "M2" and a second amount of one or more liquids "L".

[0032] According to the present invention, the third temperature of the obtained mixture "I" must be greater than or equal to the enzyme inactivation temperature of the starting material "M1".

[0033] In the present specification, "enzyme inactivation temperature" refers to the upper limit of the temperature range in which the enzyme is activated and functions, which is an inherent characteristic of the plant material used.

[0034] For rapeseed, the inactivation temperature of the enzyme is equal to about 63° C., above which the enzyme ceases to function.

[0035] For hay, the inactivation temperature of the enzyme is equal to about 60° C., above which the enzyme ceases to function.

[0036] For straw, the inactivation temperature of the enzyme is equal to about 68°C, above which the enzyme ceases to function. According to a unique aspect of the invention, the mixing step is performed in such a way that the third temperature is reached within a time interval shorter than a predetermined time interval. In other words, the mixing step is performed in such a way that the mixture passes through the above temperature range (for a specific starting material) within a time interval shorter than a predetermined time interval.

[0037] Therefore, it should be understood that the temperature change of the mixing step (wherein the first amount is heated by the second amount) must be completed within the shortest possible time interval so that the enzyme contained in the starting material "M1" is inactivated after reaching the enzyme inactivation temperature.

[0038] For example, in the case of rapeseed, the enzyme is activated at about 30°C, inactivated at about 63°C, and reaches a peak activation between 38°C and 46°C.

[0039] The third temperature must be reached in a substantially instantaneous manner within as short a time interval as possible in order to immediately inactivate the enzyme. Preferably, the predetermined time interval is less than or equal to 15 seconds, regardless of the type of starting material.

[0040] Therefore, it is necessary to set the second temperature and / or the second amount so that the starting material "M1" (which has become a component of the mixture "I") reaches the enzyme inactivation temperature.

[0041] For this purpose, the second temperature is preferably greater than or equal to 70° C. Furthermore, the second amount is preferably such that the mixture “I” obtained in the mixing step has a liquid weight percentage of between 30% and 70%.

[0042] Obviously, in order to reach the third temperature within the shortest time interval, the second amount and the second temperature may be increased.

[0043] Preferably, the mixing step is continued even after the third temperature has been reached, in any case keeping the temperature of the mixture "I" above the enzyme inactivation temperature.

[0044] In particular, the temperature of the mixture tends to decrease due to the evaporation of one or more liquids "L" caused by the operating temperature inside the mixer 200. However, the mechanical work of mixing compensates for the heat loss, so that the temperature of the mixture "I" is higher than or equal to the enzyme inactivation temperature. Alternatively, in order to maintain the temperature above the enzyme inactivation temperature, the mixer 200 can be provided with a heating device.

[0045] Preferably, the mixing step is continued for 5 to 25 minutes after the third temperature is reached.

[0046] Furthermore, preferably, at least one deodorant "A" may be added to the mixture "I" after the third temperature is reached in the mixing step.

[0047] The deodorant "A" may be one or more of: vapor (especially water vapor), inert gas (especially carbon dioxide), and / or polar solvent (especially hexane).

[0048] For this purpose, the mixer 200 may include an adding device 220, such as a nozzle for supplying the above-mentioned deodorant "A".

[0049] According to one aspect of the invention, a step of diluting the mixture "I" with one or more diluents, in particular water, may be performed after or simultaneously with the mixing step.

[0050] Preferably, after the dilution step, the weight percentage of one or more liquids "L" (especially water) in the mixture "I" is between 70% and 90%. Advantageously, the dilution allows the mixture "I" to have optimal rheological properties so as to operate effectively in the subsequent steps of the method, which will become more apparent in the following description.

[0051] like Figure 1 As shown, the conveyor belt 300 is arranged downstream of the mixer 200. In particular: the mixer 200 has a supply device, such as a screw feeder, for supplying the mixture "I" onto the processing belt so as to form a continuous layer "S1" of the mixture on the conveying surface of the conveyor belt 300.

[0052] Preferably, the thickness of the continuous layer "S1" is preferably between 100 microns and 800 microns. Advantageously, the limited thickness allows the continuous layer "S1" to dry uniformly.

[0053] The conveyor belt 300 is configured to convey the continuous layer "S1" through one or more drying spaces "V1", "V2" arranged in series, wherein each drying space "V1", "V2" is defined by a respective dryer 401, 402, to obtain a dry continuous layer "S2" having a desired liquid percentage. One or more drying spaces "V1", "V2" define a drying path for the continuous layer "S1", thereby obtaining a dry continuous layer "S2". In terms of functionality, the dryers 401, 402 are configured to ensure that at the end of the drying process, the dry continuous layer "S2" has a predetermined humidity value. In particular, at the end of the drying process, the humidity of the dry continuous layer "S2" is between 1.2% and 2.5%, preferably equal to 1.7%.

[0054] According to one aspect of the invention, in order to optimize the drying of the successive layers "S1", the length of the drying path can be set by using a predetermined number of dryers 401, 402. Using multiple dryers in series can optimize the control of the process conditions (temperature, humidity) of the drying step.

[0055] Furthermore, in order to optimize the drying of successive layers, dryers 401 and 402 may have the same temperature profile or respective different temperature profiles.

[0056] In general, the drying time of the continuous layer "S1" conveyed through one or more drying spaces "V1", "V2" depends on multiple operating parameters, such as the starting material "M1", the thickness of the continuous layer "S1", the temperature distribution of each dryer 401, 402 and the predetermined humidity value of the drying continuous layer "S2", which will become more obvious in the following description.

[0057] Preferably, the drying time of the successive layers "S1" passing through the one or more drying spaces "V1", "V2" is between 2 minutes and 12 minutes.

[0058] like Figure 1 As shown, the apparatus 1 comprises a first dryer 401 defining a first drying space “ V1 ” and a second dryer 402 defining a second drying space “ V2 ”.

[0059] Structurally, each dryer 401, 402 has an upper drying device 401a, 402a and a lower drying device 401b, 402b. Preferably, the upper drying device 401a, 402a includes a nozzle for supplying air, and the lower drying device 401b, 402b includes a nozzle for supplying steam, especially water vapor.

[0060] The upper drying devices 401a, 402a act on the top of the continuous layer "S1", while the lower drying devices 401b, 402b act on the bottom of the conveyor belt 300, so that the continuous layer "S1" is acted on by the air jet acting on its top, and is heated by conduction through the conveyor belt 300 due to the direct contact between the conveyor belt 300 and the steam jet.

[0061] Advantageously, this configuration of the drying device allows the successive layers "S1" to be heated gradually along the drying path, ensuring progressively uniform drying and preventing oxidation phenomena that could cause the fats naturally present in the starting material "M1" to deteriorate.

[0062] In particular, the temperature of the air jet is between 95° C. and 150° C., and / or the relative humidity is between 45% and 85%.

[0063] In contrast, steam jets operate at temperatures between 100°C and 180°C.

[0064] The drying parameter values, in particular the thickness of the continuous layer "S1", the drying time and the temperature distribution of one or more dryers 401, 402 (which are set by the operating parameters of the drying devices 401a, 401b, 402a, 402b), are determined relative to the speed at which one or more liquids "L" diffuse from the interior of the continuous layer "S1" to the outer surface of the continuous layer "S1".

[0065] Control of the parameter values ​​can ensure that the temperature of the outer surface of the continuous layer "S1" does not reach a critical value, and the humidity of the outer surface of the continuous layer "S1" is not lower than 1.2%, preferably lower than 1.7%.

[0066] Advantageously, this prevents the formation of peroxides, which are catalysts for the deterioration of the fats and oils naturally present in the starting material "M1". In addition, this prevents the outer surface of the continuous layer "S1" from becoming too dry and hindering the diffusion of the one or more liquids "L" from the interior of the continuous layer "S1" to the exterior of the continuous layer "S1". In other words, this prevents the outer surface from hindering evaporation when drying and thus hindering the drying of the more internal parts of the continuous layer "S1".

[0067] Advantageously, the temperature (and thus the humidity level) of the outer surface of the continuous layer "S1" is regulated due to the latent heat of evaporation.

[0068] In order to control the operating parameter values, one or more dryers 401, 402 may comprise a plurality of sensors (not shown) for measuring the above parameters and a control unit (not shown) for managing the device 1 at least according to the measured parameter values.

[0069] Advantageously, after drying, a substantially odourless dry continuous layer "S2" is obtained.

[0070] like Figure 1 As shown, downstream of the one or more dryers 401, 402, there is also an (optional) grinding device 500 for dry grinding the dried continuous layer "S2" to obtain an odorless dry powder product with a second particle size.

[0071] The further grinding device 500 is configured to obtain a second particle size of 15 microns to 200 microns, preferably 50 microns to 140 microns.

[0072] To this end, the additional grinding device 500 may be specially equipped with a screen or other screening device configured to only allow particles smaller than a predetermined size to pass through.

[0073] Preferably, the further grinding device 500 is defined by one or more stages, in particular of the silo or hammer mill or pin mill type.

[0074] The present invention overcomes the shortcomings of the prior art and achieves the preset goals.

[0075] In particular, the method according to the invention allows the production process to be applied to reconstituted materials of plant origin other than tobacco, while guaranteeing optimal quality in terms of organoleptic aspects and controlling the characteristics of the layer obtained.

[0076] Furthermore, the equipment required to implement the method is simplified and suitable for installation in compact dimensions.

Claims

1. A method for manufacturing a plant-derived recycled material layer, comprising the following steps: - providing a first amount of a starting product (M1) consisting of solid components at a first temperature; - dry grinding the solid components of the starting product (M1) to obtain a dry powder product (M2) having a first particle size; - mixing the dry powder product (M2) with a second amount of at least one or more mixing liquids (L), in particular water, in a mixer (200), said mixing liquid (L) having a second temperature greater than the first temperature, thereby obtaining a mixture (I) having a third temperature greater than or equal to the enzyme inactivation temperature of the starting material (M1); wherein the mixing step is carried out in such a way that the third temperature is reached within a time interval shorter than the predetermined time interval; - transferring the mixture (I) onto a conveyor belt (300) to form a continuous layer (S1) of the mixture (I); - Drying the continuous layer (S1) of the mixture by conveying it through a drying space (V1, V2) while it is supportively placed on a conveyor belt (300), thereby obtaining a dried continuous layer (S2).

2. The method of claim 1, wherein: The predetermined time interval is less than or equal to 15 seconds.

3. The method according to claim 1 or 2, wherein: Even after reaching said third temperature, the mixing step is continued in order to keep the temperature of the mixture (I) above the enzyme inactivation temperature.

4. The method of claim 3, wherein: After reaching the third temperature, the mixing step is continued for 5 minutes to 25 minutes.

5. A method as claimed in any one of the preceding claims, wherein: At least one deodorant (A) is added to the mixture (I), preferably after the third temperature is reached in the mixing step; the at least one deodorant (A) preferably comprises one or more of the following: - vapour, especially water vapour; - inert gases, in particular carbon dioxide; and / or - Non-polar solvents, especially hexane.

6. A method as claimed in any one of the preceding claims, wherein: The first supply temperature is below the enzyme activation temperature of the starting material (M1), preferably, the first supply temperature is substantially equal to the ambient temperature, and / or the second supply temperature is above 65°C, preferably above 70°C.

7. A method as claimed in any one of the preceding claims, wherein: The weight percentage of one or more mixed liquids, especially water, in the mixture (I) is between 30% and 70%.

8. A method according to any one of the preceding claims, comprising, after the mixing step, a step of diluting the mixture (I) with one or more diluents, in particular water.

9. The method of claim 8, wherein: After the dilution step, the liquid weight percentage of the mixture (I) is between 70% and 90%.

10. A method as claimed in any one of the preceding claims, wherein: The first particle size is between 20 microns and 500 microns, preferably between 70 microns and 250 microns.

11. A method as claimed in any one of the preceding claims, wherein: The thickness of the continuous layer (S1) is between 100 micrometers and 800 micrometers.

12. A method as claimed in any one of the preceding claims, wherein: The drying step is carried out in two or more drying stages; the successive layers (S1) are conveyed through two or more drying spaces (V1, V2) arranged in series, preferably when the successive layers (S1) are supportedly placed on the same conveyor belt (300).

13. A method as claimed in any one of the preceding claims, wherein: The drying step is carried out by subjecting the continuous layer (S1) to jets of air acting on the top of the continuous layer (S1) and / or jets of steam acting on the bottom of the conveyor belt (300).

14. The method of claim 13, wherein: The air jet has a temperature between 95° C. and 150° C. and / or a relative humidity between 45% and 85%.

15. The method according to claim 13 or 14, wherein: The temperature of the steam jet is between 100°C and 180°C.

16. A method as claimed in any one of the preceding claims, wherein: In the drying step, the total drying time of the continuous layer (S1) passing through the drying space or spaces (V1, V2) is between 2 minutes and 12 minutes.

17. A method as claimed in any one of the preceding claims, comprising a further dry grinding step after the drying step, wherein: The dried continuous layer (S2) is preferably ground using a hammer mill or a pin mill to obtain an odorless dry powder product having a second particle size between 15 microns and 200 microns, preferably between 50 microns and 140 microns.

18. A method as claimed in any one of the preceding claims, wherein: The starting material (M1) is a plant fiber product other than tobacco, in particular straw or cellulose.

19. A method as claimed in any one of the preceding claims, wherein: The starting material (M1) is rapeseed, and wherein the enzyme inactivation temperature is about 63°C.

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