Production method for reconstituted tobacco sheets

Abstract

A production method for reproducing a press-formed tobacco sheet is provided. The production method comprises a first step for adding two or more powdery raw materials containing at least tobacco into a mixer and mixing, a second step after the first step for adding a first liquid raw material into the mixer and mixing with the two or more powdery raw materials, and a press-forming step for press-forming the raw material mixed during the second step into a press-formed tobacco sheet.

Description

Technical Field

[0001] The present invention relates to a method for producing a reconstituted tobacco sheet. Background Art

[0002] Calendering methods, casting (slurry) methods, and papermaking methods are conventionally known methods for producing reconstituted tobacco sheets. These manufacturing methods are selected according to the amount of moisture contained in the reconstituted tobacco raw material. The apparatuses for producing reconstituted tobacco sheets employed in these production methods also differ from each other.

[0003] The known calendering method is particularly suitable for reconstituted tobacco raw materials containing up to 50% moisture by volume. In the calendering method, the kneaded reconstituted tobacco raw material is calendered and formed by rotating rollers, the thickness is adjusted, and then the material is dried in a separately provided dryer.

[0004] The known casting (slurry) method is particularly suitable for reconstituted tobacco raw materials containing 50% or more moisture by volume. In the casting (slurry) method, the reconstituted tobacco raw material fluid is continuously spread on a rotating drum or a belt conveyor, leveled to a desired thickness by a member called a doctor blade, then peeled off from the rotating drum or the belt conveyor, and dried in a separately provided dryer.

[0005] The known papermaking method is particularly suitable for reconstituted tobacco raw materials containing 80% or more moisture by volume. In the papermaking method, the reconstituted tobacco raw material fluid is continuously spread on a liquid-permeable belt conveyor, the moisture is removed by squeeze rollers and the desired thickness is achieved, and then the material is dried in a separately provided dryer.

[0006] Compared with these production methods selected according to the moisture content, there are known apparatuses and methods for producing reconstituted tobacco sheets that allow reconstituted tobacco sheets of uniform thickness to be obtained via a simple production process, regardless of the amount of moisture contained in the reconstituted tobacco raw material (see PTL 1).

[0007] Citation List

[0008] Patent Document

[0009] PTL 1: International Publication No. 2022 / 019027 Summary of the Invention

[0010] Technical Problem

[0011] In the case where the reconstituted tobacco sheet is pressure-formed, as in the method disclosed in Patent Document 1 or in the calendering method, the method for producing the reconstituted pressure-formed tobacco raw material is not considered.

[0012] The object of the present invention is to provide a novel method for producing a reconstituted pressure-formed tobacco sheet.

[0013] Solution to the problem

[0014] In a first aspect, there is provided a method for producing a reconstituted pressure-formed tobacco sheet. The production method comprises: a first step of introducing two or more powdery raw materials containing at least tobacco into a mixer and mixing them therein; a second step of introducing a first liquid raw material into the mixer after the first step and mixing it with the two or more powdery raw materials; and a forming step of forming the raw materials mixed in the second step into a pressure-formed sheet.

[0015] According to the first aspect, before mixing the powdery raw materials and the first liquid raw material, the two or more powdery raw materials are mixed in the first step, so that the two or more powdery raw materials are fully mixed.

[0016] The two or more powdery raw materials may include tobacco, a binder, and additives.

[0017] In this case, the powdery raw materials and the first liquid raw material are mixed, thereby allowing the production of a tobacco raw material in which the viscosity has been increased by the binder. The additives may include, for example, one or more selected from the group consisting of pulp, cellulose (such as crystalline cellulose or cellulose powder), calcium carbonate, menthol, and powdery flavors. The additives are included in the powdery raw materials to allow an increase in the strength of the tobacco sheet or to allow the provision of a flavor.

[0018] The first liquid raw material may include an aerosol source, water, and additives.

[0019] In this case, the powdery raw materials and the first liquid raw material are mixed, thereby allowing the production of a tobacco raw material in which a larger amount of aerosol is generated. The aerosol source may include, for example, one or more selected from the group consisting of glycerol and propylene glycol. The additives may also include, for example, a liquid flavor. The liquid flavor is included in the liquid raw material to allow the flavoring of the tobacco sheet.

[0020] The second step may include introducing the first liquid raw material formed by premixing an aerosol source, water, and additives into the mixer.

[0021] In this case, the aerosol source, water, and additives contained in the first liquid raw material are premixed, so that the powdery raw materials and the first liquid raw material are more uniformly mixed.

[0022] The production method may include: a step of feeding the raw materials mixed in the second step into an extruder; and in addition, a step of adding a second liquid raw material to the raw materials fed into the extruder.

[0023] The raw material must have a moisture content suitable for the extrusion process in order to extrude the raw material in an extruder. On the other hand, the raw material that is wet enough to be extruded in the extruder will be highly viscous and will therefore be difficult to handle outside the extruder. Thus, adding a second liquid raw material to the raw material in the extruder will allow the moisture content of the raw material to be adjusted in the extruder and will therefore allow the amount of the first liquid raw material mixed in the mixer to be reduced. As a result, it is possible to prevent the raw material in the mixer from becoming highly viscous, thus allowing the raw material to be easily handled when feeding the raw material from the mixer to the extruder.

[0024] The second liquid raw material may comprise water.

[0025] This will allow the amount of the first liquid raw material mixed in the mixer to be reduced. As a result, it is possible to prevent the raw material in the mixer from becoming highly viscous, thus allowing the raw material to be easily handled when feeding the raw material from the mixer to the extruder. The second liquid raw material may comprise one or more selected from the group consisting of: water, glycerol, propylene glycol, binder solution, and liquid flavor.

[0026] The forming step may include: extruding the raw material mixed in the second step into a mold through an extruder; and extruding the raw material from the mold into a sheet form.

[0027] The forming step may include: extruding the raw material mixed in the second step through an extruder; and forming the raw material extruded from the extruder into a sheet by at least a pair of vertically opposed calendering rolls.

[0028] The forming step may include: extruding the raw material mixed in the second step through an extruder; and forming the raw material extruded from the extruder into a sheet by passing the raw material between two or more horizontally adjacent calendering rolls.

[0029] A second aspect provides a method for producing a reconstituted pressure-formed tobacco sheet. The production method includes: a first step of introducing a first liquid raw material into a mixer; after the first step, a second step of introducing at least a powdery raw material containing tobacco into the mixer and mixing it with the first liquid raw material; and a forming step of forming the raw material mixed in the second step into a pressure-formed sheet.

[0030] According to the second aspect, the powdery raw material is mixed with the first liquid raw material, so that it is possible to prevent the powdery raw material from caking and to mix the raw material more uniformly.

[0031] The powdery raw material may comprise tobacco, binder, and additive.

[0032] In this case, the powdery raw material and the first liquid raw material are mixed, thereby allowing the production of a tobacco raw material in which the viscosity has been increased by a binder. The additive may include, for example, one or more selected from the group consisting of pulp, cellulose (such as crystalline cellulose or cellulose powder), calcium carbonate, menthol, and powdery flavor. The additive is included in the powdery raw material to allow an increase in the strength of the tobacco sheet or to allow the provision of flavor.

[0033] The second step may include separately introducing each of the tobacco, the binder, and the additive into a mixer and mixing them with the first liquid raw material.

[0034] In this case, the powdery raw material is mixed separately with the first liquid raw material, thereby enabling further prevention of caking of the powdery raw material and more uniform mixing of the raw materials.

[0035] The first liquid raw material may include an aerosol source, water, and an additive.

[0036] In this case, the powdery raw material and the first liquid raw material are mixed, thereby allowing the production of a tobacco raw material in which a larger amount of aerosol is generated. The aerosol source may include, for example, one or more selected from the group consisting of glycerol and propylene glycol. The additive may also include, for example, a liquid flavor. The liquid flavor is included in the liquid raw material to allow flavoring of the tobacco sheet.

[0037] The production method may include: a step of feeding the raw materials mixed in the second step into an extruder; and in addition, a step of adding a second liquid raw material to the raw materials fed into the extruder.

[0038] The raw materials must have a moisture content suitable for the extrusion process in order to extrude the raw materials in the extruder. On the other hand, the raw materials that are sufficiently moist to be extruded in the extruder will be highly viscous and will therefore be difficult to handle outside the extruder. Therefore, adding the second liquid raw material to the raw materials in the extruder will allow adjustment of the moisture content of the raw materials in the extruder and will therefore allow a reduction in the amount of the first liquid raw material mixed in the mixer. As a result, it is possible to prevent the raw materials in the mixer from becoming highly viscous, thereby allowing easy handling of the raw materials when feeding the raw materials from the mixer into the extruder.

[0039] The second liquid raw material may include water.

[0040] This will allow a reduction in the amount of the first liquid raw material mixed in the mixer. As a result, it is possible to prevent the raw materials in the mixer from becoming highly viscous, thereby allowing easy handling of the raw materials when feeding the raw materials from the mixer into the extruder. The second liquid raw material may include one or more selected from the group consisting of water, glycerol, propylene glycol, binder solution, and liquid flavor.

[0041] The forming step may include: extruding the raw material mixed in the second step into a mold through an extruder; and extruding the raw material from the mold into a sheet form.

[0042] The forming step may include: extruding the raw material mixed in the second step through an extruder; and forming the raw material extruded from the extruder into a sheet by at least a pair of vertically opposed calendering rolls.

[0043] The forming step may include: extruding the raw material mixed in the second step through an extruder; and forming the raw material extruded from the extruder into a sheet by passing it between two or more horizontally adjacent calendering rolls.

[0044] A third aspect provides a method for producing a reconstituted pressure-formed tobacco sheet. The production method includes: a first step of introducing water and an adhesive into a mixer and mixing them therein to swell the adhesive; after the first step, a second step of introducing a first liquid raw material and a powdery raw material containing at least tobacco into the mixer and mixing them with the already swollen adhesive; and a forming step of forming the raw material mixed in the second step into a pressure-formed sheet.

[0045] According to the third aspect, the adhesive is premixed with water and swollen, and the first liquid raw material and the powdery raw material are mixed while the adhesive function of the adhesive is in effect, thereby increasing the viscosity of the raw material. As a result, the raw material is easier to handle and is also easily extruded through an extruder. The viscosity of the raw material is also increased, thereby enhancing the strength of the tobacco sheet. As used herein, examples of adhesives that can be used include one or more adhesives selected from the group consisting of: tamarind gum, guar gum, locust bean gum, xanthan gum, glucomannan, natural gellan gum, gum arabic, shellac, lecithin, gluten, CMC, HPC-L, HPC-H, pullulan, sorbitol, guar gum, gelatinized waxy corn starch, glycerol gum, hydroxypropyl starch, shellac, hydroxypropyl potato starch, phosphate-crosslinked tapioca starch.

[0046] The powdery raw material may contain tobacco and additives.

[0047] In this case, the powdery raw material and the first liquid raw material are mixed, thereby allowing the production of a tobacco raw material in which the viscosity has been increased by the adhesive. The additives may include, for example, one or more selected from the group consisting of: pulp, cellulose (such as crystalline cellulose or cellulose powder), calcium carbonate, menthol, and powdery flavorings. The additives are included in the powdery raw material to allow an increase in the strength of the tobacco sheet or to allow the provision of a flavor.

[0048] The second step may include introducing each of the tobacco and the additive separately into a mixer to be mixed with the already swollen binder.

[0049] In this case, the powdery raw materials are each separately mixed with the already swollen binder, thereby further preventing the powdery raw materials from caking and enabling the raw materials to be more uniformly mixed.

[0050] The first liquid raw material may contain an aerosol source and an additive.

[0051] In this case, the already swollen binder, the powdery raw materials, and the first liquid raw material are mixed, thereby allowing the production of a tobacco raw material in which a larger amount of aerosol is generated. The aerosol source may include, for example, one or more selected from the group consisting of glycerol and propylene glycol. The additive may also include, for example, a liquid flavor. The liquid flavor is included in the liquid raw material to allow the tobacco sheet to be flavored. The first liquid raw material may further contain water.

[0052] The second step may include introducing each of the first liquid raw material and the powdery raw materials separately into a mixer to be mixed with the already swollen binder.

[0053] In this case, the first liquid raw material and the powdery raw materials are each separately mixed, thereby enabling the raw materials to be more uniformly mixed.

[0054] The second step may include introducing the first liquid raw material into a mixer before the powdery raw materials to be mixed with the already swollen binder.

[0055] In this case, the powdery raw materials are introduced and mixed with the already swollen binder and the liquid raw material, thereby preventing the powdery raw materials from caking and enabling the raw materials to be more uniformly mixed.

[0056] The production method may include: a step of feeding the raw materials mixed in the second step into an extruder; and further a step of adding a second liquid raw material to the raw materials fed into the extruder.

[0057] The raw materials must have a moisture content suitable for the extrusion process in order to extrude the raw materials in the extruder. On the other hand, the raw materials that are sufficiently moist to be extruded in the extruder will be highly viscous and will therefore be difficult to handle outside the extruder. Therefore, adding the second liquid raw material to the raw materials in the extruder will allow the moisture content of the raw materials in the extruder to be adjusted, and therefore allow the amount of the first liquid raw material mixed in the mixer to be reduced. As a result, it is possible to prevent the raw materials in the mixer from becoming highly viscous, thereby allowing the raw materials to be easily handled when feeding the raw materials from the mixer into the extruder.

[0058] The second liquid raw material may contain water.

[0059] This will allow reducing the amount of the first liquid raw material mixed in the mixer. As a result, it is possible to prevent the raw material in the mixer from becoming highly viscous, thus allowing easy handling of the raw material when feeding the raw material from the mixer to the extruder. The second liquid raw material may include one or more selected from the group consisting of: water, glycerol, propylene glycol, binder solution, and liquid flavor.

[0060] The forming step may include: a step of extruding the raw material mixed in the second step into a mold through an extruder; and a step of extruding the raw material from the mold into a sheet form.

[0061] The forming step may include: a step of extruding the raw material mixed in the second step through an extruder; and a step of forming the raw material extruded from the extruder into a sheet by at least a pair of vertically opposed calendering rolls.

[0062] The forming step may include: a step of extruding the raw material mixed in the second step through an extruder; and a step of forming the raw material extruded from the extruder into a sheet by passing it between two or more horizontally adjacent calendering rolls.

[0063] A fourth aspect provides a method for producing a reconstituted pressure-formed tobacco sheet. The production method includes: a mixing step of introducing a first liquid raw material and a powdery raw material containing at least tobacco into a mixer and mixing them therein; a step of feeding the raw material mixed in the mixing step into an extruder; in addition, a step of adding a second liquid raw material to the raw material fed into the extruder; and a forming step of forming the raw material extruded from the extruder into a pressure-formed sheet.

[0064] The raw material must have a moisture content suitable for the extrusion process in order to extrude the raw material in the extruder. On the other hand, the raw material that is sufficiently moist to be extruded in the extruder will be highly viscous and thus difficult to handle outside the extruder. Therefore, the fourth aspect allows adjusting the moisture content of the raw material in the extruder and thus allows reducing the amount of the first liquid raw material mixed in the mixer. As a result, it is possible to prevent the raw material in the mixer from becoming highly viscous, thus allowing easy handling of the raw material when feeding the raw material from the mixer to the extruder.

[0065] The second liquid raw material may include water.

[0066] This will allow reducing the amount of the first liquid raw material mixed in the mixer. As a result, it is possible to prevent the raw material in the mixer from becoming highly viscous, thus allowing easy handling of the raw material when feeding the raw material from the mixer to the extruder. The second liquid raw material may include one or more selected from the group consisting of: water, glycerol, propylene glycol, binder solution, and liquid flavor.

[0067] The mixing step may include: a first step of introducing two or more powdery raw materials into a mixer and mixing them therein; and a second step of introducing a first liquid raw material into the mixer and mixing it with the powdery raw materials after the first step.

[0068] In this case, two or more powdery raw materials are mixed in the first step so that the powdery raw materials are fully mixed, and then the powdery raw materials are mixed with the first liquid raw material.

[0069] The second step may include introducing a first liquid raw material formed by premixing an aerosol source, water, and an additive into the mixer.

[0070] In this case, the aerosol source, water, and additive contained in the first liquid raw material are premixed so that the powdery raw materials and the first liquid raw material are more uniformly mixed.

[0071] The mixing step may include: a first step of introducing the first liquid raw material into the mixer; and a second step of introducing the powdery raw materials into the mixer and mixing them with the first liquid material after the first step.

[0072] In this case, the powdery raw materials are mixed with the first liquid raw material so that caking of the powdery raw materials can be prevented and the raw materials are more uniformly mixed.

[0073] The second step may include separately introducing each of tobacco, a binder, and an additive into the mixer and mixing them with the first liquid raw material.

[0074] In this case, the powdery raw materials are separately mixed with the first liquid raw material so that caking of the powdery raw materials can be further prevented and the raw materials are more uniformly mixed.

[0075] The mixing step may include: a first step of introducing water and a binder into the mixer and mixing them therein to swell the binder; and a second step of introducing the first liquid raw material and the powdery raw materials into the mixer and mixing them with the swollen binder after the first step.

[0076] In this case, the binder is premixed with water and swollen, and the first liquid raw material and the powdery raw materials are mixed while the binding function of the binder is in effect, thereby increasing the viscosity of the raw materials. As a result, the raw materials are easily extruded through an extruder. The viscosity of the raw materials is also increased, thereby enhancing the strength of the tobacco sheet.

[0077] The second step may include separately introducing each of tobacco and an additive into the mixer to mix them with the swollen binder.

[0078] In this case, the powdery raw materials are each individually mixed with the already swollen binder, so that it is possible to further prevent the powdery raw materials from caking and to mix the raw materials more uniformly.

[0079] The second step may include introducing each of the first liquid raw material and the powdery raw material individually into a mixer to mix with the already swollen binder.

[0080] In this case, the first liquid raw material and the powdery raw material are each individually mixed, so that the raw materials are mixed more uniformly.

[0081] The second step may include introducing the first liquid raw material into the mixer before the powdery raw material to mix with the already swollen binder.

[0082] In this case, the powdery raw material is introduced and mixed with the already swollen binder and the first liquid raw material, so that it is possible to prevent the powdery raw material from caking and to mix the raw materials more uniformly.

[0083] The forming step may include: the step of extruding the raw material into a mold through an extruder; and the step of extruding the raw material from the mold into a sheet form.

[0084] The forming step may include: the step of extruding the raw material through an extruder; and the step of forming the raw material extruded from the extruder into a sheet by at least a pair of vertically opposed calendering rolls.

[0085] The forming step may include: the step of extruding the raw material through an extruder; and the step of forming the raw material extruded from the extruder into a sheet by passing it between two or more horizontally adjacent calendering rolls. Description of the Drawings

[0086] Figure 1 is a schematic diagram of a system for producing a reconstituted pressure-formed tobacco sheet.

[0087] Figure 2 is a flowchart of a method for producing a reconstituted pressure-formed tobacco sheet using a mixer, an extruder, and a mold according to a first embodiment.

[0088] Figure 3 is a flowchart of a method for producing a reconstituted pressure-formed tobacco sheet using a mixer, an extruder, and a mold according to a second embodiment.

[0089] Figure 4 is a flowchart of a method for producing a reconstituted pressure-formed tobacco sheet using a mixer, an extruder, and a mold according to a third embodiment.

[0090] Figure 5Is a flowchart of a method for producing a reconstituted pressure-formed tobacco sheet using a mixer, an extruder, and a die according to a fourth embodiment. Detailed Description

[0091] Embodiments of the present invention will be described below with reference to the accompanying drawings. In the following-described drawings, the same or corresponding components are denoted by the same reference signs and will not be described repeatedly.

[0092] Figure 1 Is a schematic diagram of a system for producing a reconstituted pressure-formed tobacco sheet. As Figure 1 shown, the reconstituted pressure-formed tobacco sheet production system 100 includes: a first grinder 10; a second grinder 20; a classifier 30; a mixer 40; an extruder 50; a die 60; a take-off machine 70; and a dryer 80. In this production system 100, first, tobacco is ground to a predetermined particle size by the first grinder 10. Then, the ground tobacco particles are ground to a smaller particle size in the second grinder 20. The tobacco ground by the second grinder 20 is classified by the classifier 30. The tobacco removed by the classifier 30 is ground again in the first grinder 10 and the second grinder 20. The tobacco classified by the classifier 30 is mixed with an additive in, for example, the mixer 40 to produce a raw material for the reconstituted pressure-formed tobacco sheet.

[0093] The raw material is fed into the extruder 50 and extruded into the die 60 by the extruder 50. The raw material is extruded from the die 60 in the form of a sheet. The raw material in the form of a sheet discharged from the die 60 is taken up by a take-up machine 70 and dried in the dryer 80 in a subsequent stage. Thereby, a reconstituted pressure-formed tobacco sheet is produced.

[0094] Figure 2 Is a flowchart of a method for producing a reconstituted pressure-formed tobacco sheet using the mixer 40, the extruder 50, and the die 60 according to a first embodiment. In the method for producing a reconstituted pressure-formed tobacco sheet according to the first embodiment, first, two or more powdery raw materials containing at least tobacco are introduced into the mixer 40 and mixed therein (first step: step S201). The tobacco can be tobacco leaves of any shape, but is preferably tobacco particles that have been classified in the Figure 1 classifier 30 as shown.

[0095] After the first step, the first liquid raw material is then introduced into the mixer 40 and mixed with two or more powdered raw materials (second step: step S202). Thus, a raw material for reconstituting a pressure-formed tobacco sheet is produced. The raw material mixed in the second step is formed into a pressure-formed sheet (forming step). Specifically, the raw material mixed in the second step is fed into an extruder 50 (step S203). The raw material can be highly viscous and can thus be fed into the extruder 50 by a carrier machine, such as a belt conveyor.

[0096] The raw material fed into the extruder 50 is extruded by the extruder 50 into the form of a sheet. According to Figure 2 the production method shown, before mixing the powdered raw materials and the first liquid raw material, two or more powdered raw materials are mixed in the first step S201, so that the two or more powdered raw materials are fully mixed. Specifically, the raw material fed into the extruder 50 is extruded by the extruder 50 into a die 60 (step S205) and extruded from the die 60 into the form of a sheet (step S206).

[0097] As Figure 2 shown, in addition, a second liquid raw material can be added to the raw material fed into the extruder 50 (step S204). The raw material must have a moisture content suitable for the extrusion process in order to be extruded in the extruder 50. On the other hand, the raw material that is sufficiently moist to be extruded in the extruder 50 will be highly viscous and will thus be difficult to handle outside the extruder 50 (for example, when being conveyed from the mixer 40 to the extruder 50). Therefore, adding the second liquid raw material to the raw material in the extruder 50 will allow the moisture content of the raw material to be adjusted in the extruder 50 and will thus allow the amount of the first liquid raw material mixed in the mixer 40 to be reduced. As a result, it is possible to prevent the raw material in the mixer 40 from becoming highly viscous, thus allowing the raw material to be easily handled when feeding the raw material from the mixer 40 into the extruder 50.

[0098] The second liquid raw material can contain water. This will allow the amount of the first liquid raw material mixed in the mixer 40 to be reduced. As a result, it is possible to prevent the raw material in the mixer 40 from becoming highly viscous, thus allowing the raw material to be easily handled when feeding the raw material from the mixer 40 into the extruder 50. The second liquid raw material can contain one or more selected from the group consisting of: water, glycerol, propylene glycol, an adhesive solution, and a liquid flavor.

[0099] In Figure 2In the production method shown, the two or more powdery raw materials preferably include tobacco, a binder, and an additive. In this case, in step S202, the two or more powdery raw materials and the first liquid raw material are mixed, thereby allowing the production of a tobacco raw material in which the viscosity has been increased by the binder. The additive may include, for example, one or more selected from the group consisting of pulp, cellulose (such as crystalline cellulose or cellulose powder), calcium carbonate, menthol, and powdery flavor. The additive is included in the powdery raw material to allow an increase in the strength of the tobacco sheet or to allow the provision of a flavor.

[0100] In Figure 2 In the production method shown, the first liquid raw material preferably includes an aerosol source, water, and an additive. In this case, in step S202, the two or more powdery raw materials and the first liquid raw material are mixed, thereby allowing the production of a tobacco raw material in which a larger amount of aerosol is generated. The aerosol source may include, for example, one or more selected from the group consisting of glycerol and propylene glycol. The additive may also include, for example, a liquid flavor. The liquid flavor is included in the liquid raw material to allow the flavoring of the tobacco sheet.

[0101] In the second step (step S202), the first liquid raw material formed by premixing the aerosol source, water, and additive may be introduced into the mixer 40. In this case, the aerosol source, water, and additive contained in the first liquid raw material are premixed, thereby allowing the powdery raw material and the first liquid raw material to be more uniformly mixed.

[0102] Instead of steps S205 and S206, Figure 2 The production method shown may include a step of extruding the raw material mixed in the second step (step S202) through an extruder 50, and a step of forming the raw material extruded from the extruder 50 into a sheet by at least a pair of vertically opposed rollers. More specifically, the raw material may be formed into a sheet in stages by three sets of calender rollers (i.e., six rollers). Instead of steps S205 and S206, Figure 2 The production method shown may also include a step of extruding the raw material mixed in the second step (step S202) through an extruder 50, and a step of forming the raw material extruded from the extruder 50 into a sheet by passing it between two or more horizontally adjacent calender rollers. More specifically, the raw material may be formed into a sheet in stages by passing it through each of four horizontally adjacent calender rollers.

[0103] Figure 3is a flowchart of a method for manufacturing a reconstituted pressure-formed tobacco sheet in a mixer 40, an extruder 50, and a die 60 according to a second embodiment. In the method for producing a reconstituted pressure-formed tobacco sheet according to the second embodiment, first, a first liquid raw material is introduced into the mixer 40 (first step: step S301). After the first step, then a powdery starting material containing at least tobacco is introduced into the mixer 40 and mixed with the first liquid raw material (second step: step S302). Thereby, a raw material for the reconstituted pressure-formed tobacco sheet is produced. The tobacco can be tobacco leaves of any shape, but is preferably tobacco particles that have been graded in the Figure 1 grading machine 30 shown.

[0104] The raw material mixed in the second step is formed into a pressure-formed sheet (forming step). Specifically, the raw material mixed in the second step is fed into the extruder 50 (step S303). The raw material can be highly viscous and can thus be fed into the extruder 50 by a carrier machine such as a belt conveyor. The raw material fed into the extruder 50 is extruded by the extruder 50 into the form of a sheet. According to the Figure 3 production method shown, the powdery raw material is mixed with the first liquid raw material, thereby making it possible to prevent the powdery raw material from caking and to mix the raw materials more uniformly. Specifically, the raw material fed into the extruder 50 is extruded by the extruder 50 into the die 60 (step S305) and is extruded from the die 60 into the form of a sheet (step S306).

[0105] As Figure 3 shown, in addition, a second liquid raw material can be added to the raw material fed into the extruder 50 (step S304). The raw material must have moisture suitable for the extrusion process in order to extrude the raw material in the extruder 50. On the other hand, the raw material that is sufficiently moist to be extruded in the extruder 50 will be highly viscous and will thus be difficult to handle outside the extruder 50 (for example, when being transported from the mixer 40 to the extruder 50). Therefore, adding the second liquid raw material to the raw material in the extruder 50 will allow the moisture of the raw material to be adjusted in the extruder 50 and will thus allow the amount of the first liquid raw material mixed in the mixer 40 to be reduced. As a result, it is possible to prevent the raw material in the mixer 40 from becoming highly viscous, thereby allowing the raw material to be easily handled when feeding the raw material from the mixer 40 to the extruder 50.

[0106] The second liquid raw material can contain water. This will allow the amount of the first liquid raw material mixed in the mixer 40 to be reduced. As a result, it is possible to prevent the raw material in the mixer 40 from becoming highly viscous, thereby allowing the raw material to be easily handled when feeding the raw material from the mixer 40 to the extruder 50. The second liquid raw material can contain one or more selected from the group consisting of: water, glycerin, propylene glycol, binder solution, and liquid flavor.

[0107] In Figure 3 the production method shown, the powdery raw material preferably contains tobacco, a binder, and an additive. In this case, in step S302, the powdery raw material and the first liquid raw material are mixed, thereby allowing the production of a tobacco raw material in which the viscosity has been increased by the binder. The additive may include, for example, one or more selected from the group consisting of pulp, cellulose (such as crystalline cellulose or cellulose powder), calcium carbonate, menthol, and powdery flavor. The additive is included in the powdery raw material to allow an increase in the strength of the tobacco sheet or to allow the provision of a flavor.

[0108] The second step (step S302) may include separately introducing each of tobacco, the binder, and the additive into the mixer 40 and mixing them with the first liquid raw material. In this case, the powdery raw material is mixed with the first liquid raw material separately, thereby making it possible to further prevent the powdery raw material from caking and to mix the raw materials more uniformly.

[0109] In Figure 3 the production method shown, the first liquid raw material preferably contains an aerosol source, water, and an additive. In this case, in step S302, the powdery raw material and the first liquid raw material are mixed, thereby allowing the production of a tobacco raw material in which a larger amount of aerosol is generated. The aerosol source may include, for example, one or more selected from the group consisting of glycerin and propylene glycol. The additive may also include, for example, a liquid flavor. The liquid flavor is included in the liquid raw material to allow flavoring of the tobacco sheet.

[0110] Instead of steps S305 and S306, Figure 3 the production method shown may include a step of extruding the raw materials mixed in the second step (step S302) through an extruder 50, and a step of forming the raw materials extruded from the extruder 50 into a sheet by at least a pair of vertically opposed rollers. More specifically, the raw materials may be formed into a sheet in stages by three sets of calender rollers (i.e., six rollers). Instead of steps S305 and S306, Figure 3 the production method shown may also include a step of extruding the raw materials mixed in the second step (step S302) through an extruder 50, and a step of forming the raw materials extruded from the extruder 50 into a sheet by passing them between two or more horizontally adjacent calender rollers. More specifically, the raw materials may be formed into a sheet in stages by passing them through each of four horizontally adjacent calender rollers.

[0111] Figure 4It is a flowchart of a method for manufacturing a reconstituted pressure-formed tobacco sheet in a mixer 40, an extruder 50, and a die 60 according to the third embodiment. In the method for producing a reconstituted pressure-formed tobacco sheet of the third embodiment, first, water and an adhesive are introduced into the mixer 40 and mixed to swell the adhesive (first step: step S401). After the first step, then a first liquid raw material and a powdery starting material containing at least tobacco are introduced into the mixer 40 and mixed with the already swollen adhesive (second step: step S402). Thus, a raw material for the reconstituted pressure-formed tobacco sheet is produced. The tobacco can be tobacco leaves of any shape, but is preferably tobacco particles that have been classified in the classifier 30 shown in Figure 1 shown.

[0112] The raw material mixed in the second step is formed into a pressure-formed sheet (forming step). Specifically, the raw material mixed in the second step is fed into the extruder 50 (step S403). The raw material can be highly viscous and can therefore be fed into the extruder 50 by a carrier machine such as a belt conveyor. The raw material fed into the extruder 50 is extruded by the extruder 50 into the form of a sheet. According to the Figure 4 shown production method, the adhesive is premixed with water and swollen, and the first liquid raw material and the powdery raw material are mixed while the adhesive function of the adhesive takes effect, thereby increasing the viscosity of the raw material. As a result, the raw material is easier to handle, and the raw material is also easily extruded by the extruder 50. The viscosity of the raw material is also increased, thereby enhancing the strength of the tobacco sheet. Specifically, the raw material fed into the extruder 50 is extruded by the extruder 50 into the die 60 (step S405), and is extruded from the die 60 into the form of a sheet (step S406).

[0113] As Figure 4 shown, in addition, a second liquid raw material can be added to the raw material fed into the extruder 50 (step S404). The raw material must have moisture suitable for the extrusion process in order to extrude the raw material in the extruder 50. On the other hand, the raw material that is wet enough to be extruded in the extruder 50 will be highly viscous and will therefore be difficult to handle outside the extruder 50 (for example, when being transported from the mixer 40 to the extruder 50). Therefore, adding the second liquid raw material to the raw material in the extruder 50 will allow the moisture of the raw material to be adjusted in the extruder 50, and will therefore allow the amount of the first liquid raw material mixed in the mixer 40 to be reduced. As a result, it is possible to prevent the raw material in the mixer 40 from becoming highly viscous, thereby allowing the raw material to be easily handled when feeding the raw material from the mixer 40 into the extruder 50.

[0114] The second liquid raw material may contain water. This will allow reducing the amount of the first liquid raw material mixed in the mixer 40. As a result, it is possible to prevent the raw materials in the mixer 40 from becoming highly viscous, thus allowing the raw materials to be easily handled when feeding the raw materials from the mixer 40 to the extruder 50. The second liquid raw material may contain one or more selected from the group consisting of: water, glycerin, propylene glycol, an adhesive solution, and a liquid flavor.

[0115] In Figure 4 In the production method shown, the powdery raw material preferably contains tobacco and an additive. In this case, the powdery raw material and the first liquid raw material are mixed in step S402, thus allowing the production of a tobacco raw material in which the viscosity has been increased by an adhesive. The additive may contain, for example, one or more selected from the group consisting of: pulp, cellulose (such as crystalline cellulose or cellulose powder), calcium carbonate, menthol, and a powdery flavor. The additive is included in the powdery raw material to allow increasing the strength of the tobacco sheet or to allow providing a flavor.

[0116] In the second step (step S402), the tobacco and the additive may be introduced into the mixer 40 separately and mixed with the already swollen adhesive. In this case, the powdery raw materials are mixed with the already swollen adhesive separately, thus making it possible to further prevent the powdery raw materials from caking and to mix the raw materials more uniformly.

[0117] In Figure 4 In the production method shown, the first liquid raw material preferably contains an aerosol source and an additive. In this case, the already swollen adhesive, the powdery raw material, and the first liquid raw material are mixed in step S402, thus allowing the production of a tobacco raw material in which a larger amount of aerosol is generated. The aerosol source may contain, for example, one or more selected from the group consisting of glycerin and propylene glycol. The additive may also contain, for example, a liquid flavor. The liquid flavor is included in the liquid raw material to allow flavoring the tobacco sheet.

[0118] In the second step (step S402), the first liquid raw material and the powdery raw material may be introduced into the mixer 40 separately and mixed with the already swollen adhesive. By mixing the first liquid raw material and the powdery raw material separately in this way, the raw materials are mixed more uniformly. In addition, in this case, the first liquid raw material is preferably introduced into the mixer 40 before the powdery raw material to be mixed with the already swollen adhesive in the second step (step S402). By introducing the powdery raw material in this way and mixing it with the already swollen adhesive and the liquid raw material, it is possible to prevent the powdery raw materials from caking and to mix the raw materials more uniformly.

[0119] Instead of step S405 and step S406, Figure 4The production method shown may include a step of extruding the raw materials mixed in the second step (step S402) through an extruder 50, and a step of forming the raw materials extruded from the extruder 50 into a sheet by at least a pair of vertically opposed rollers. More specifically, the raw materials may be formed into a sheet in stages by three sets of calender rollers (i.e., six rollers). Instead of steps S405 and S406, Figure 4 The production method shown may also include a step of extruding the raw materials mixed in the second step (step S402) through an extruder 50, and a step of forming the raw materials extruded from the extruder 50 into a sheet by passing the raw materials between two or more horizontally adjacent calender rollers. More specifically, the raw materials may be formed into a sheet in stages by passing through each of four horizontally adjacent calender rollers.

[0120] Figure 5 is a flowchart of a method for producing a reconstituted pressure-formed tobacco sheet in a mixer 40, an extruder 50, and a die 60 according to the fourth embodiment. In the method for producing a reconstituted pressure-formed tobacco sheet of the fourth embodiment, first, at least a powdery raw material containing tobacco and a first liquid raw material are introduced into the mixer 40 and mixed therein (mixing step: step S501). The tobacco may be tobacco leaves of any shape, but preferably tobacco particles that have been graded in the Figure 1 grading machine 30 shown. Then, the raw materials mixed in the mixing step are fed into the extruder 50 (step S502). The raw materials may be highly viscous and may thus be fed into the extruder 50 by a carrier machine, such as a belt conveyor.

[0121] In the fourth embodiment herein, in addition, a second liquid raw material is added to the raw materials fed into the extruder 50 (step S503). The raw materials extruded from the extruder 50 are formed into a pressure-formed sheet (forming step). Specifically, the raw materials fed into the extruder 50 are extruded in the form of a sheet. More specifically, the raw materials fed into the extruder 50 are extruded into the die 60 through the extruder 50 (step S504), and are extruded from the die 60 in the form of a sheet (step S505).

[0122] As described above, the raw materials must have moisture suitable for the extrusion process in order to extrude the raw materials in the extruder 50. On the other hand, the raw materials that are sufficiently moist to be extruded in the extruder 50 will be highly viscous and will thus be difficult to handle outside the extruder 50 (e.g., when being transported from the mixer 40 to the extruder 50). Therefore, the fourth embodiment allows the moisture of the raw materials to be adjusted in the extruder 50, and thus allows the amount of the first liquid raw material mixed in the mixer 40 to be reduced. As a result, it is possible to prevent the raw materials in the mixer 40 from becoming highly viscous, thereby allowing the raw materials to be easily handled when feeding the raw materials from the mixer 40 into the extruder 50.

[0123] The second liquid raw material in step S503 may include water. This will allow reducing the amount of the first liquid raw material mixed in the mixer 40. As a result, it is possible to prevent the raw materials in the mixer 40 from becoming highly viscous, thereby allowing easy handling of the raw materials when feeding the raw materials from the mixer 40 into the extruder 50. The second liquid raw material may include one or more selected from the group consisting of: water, glycerol, propylene glycol, an adhesive solution, and a liquid flavor.

[0124] The mixing step (step S501) may include: a first step of introducing two or more powdery raw materials into the mixer 40 and mixing them therein; and a second step of introducing the first liquid raw material into the mixer 40 and mixing it with the powdery raw materials after the first step. In this case, in the first step, two or more powdery raw materials are mixed so that the powdery raw materials are sufficiently mixed, and then the powdery raw materials are mixed with the first liquid raw material. In the second step, the first liquid raw material formed by premixing an aerosol source, water, and an additive may be introduced into the mixer 40. In this case, the aerosol source, water, and additive contained in the first liquid raw material are premixed, so that the powdery raw materials and the first liquid raw material are more uniformly mixed.

[0125] Alternatively, the mixing step (step S501) may include: a first step of introducing the first liquid raw material into the mixer 40; and a second step of introducing the powdery raw materials into the mixer 40 and mixing them with the first liquid material after the first step. In this case, the powdery raw materials are mixed with the first liquid raw material, thereby preventing the powdery raw materials from caking and making the raw materials more uniformly mixed. In the second step, tobacco, an adhesive, and an additive may be individually introduced into the mixer 40 and mixed with the first liquid raw material. In this case, the powdery raw materials are individually mixed with the first liquid raw material, thereby further preventing the powdery raw materials from caking and making the raw materials more uniformly mixed.

[0126] Alternatively, the mixing step (step S501) may include: a first step of introducing water and an adhesive into a mixer 40 and mixing them therein to swell the adhesive; and a second step of, after the first step, introducing a first liquid raw material and a powdery raw material into the mixer 40 and mixing them with the already swollen adhesive. In this case, the adhesive is premixed with water and swollen, and the first liquid raw material and the powdery raw material are mixed while the adhesive function of the adhesive is in effect, thereby increasing the viscosity of the raw materials. As a result, the raw materials are easily extruded through an extruder. The viscosity of the raw materials is also increased, thereby enhancing the strength of the tobacco sheet. In the second step, tobacco and additives may be individually introduced into the mixer 40 and mixed with the already swollen adhesive. In this case, the powdery raw materials are individually mixed with the already swollen adhesive, thereby further preventing the powdery raw materials from caking and mixing the raw materials more uniformly.

[0127] In the second step, the first liquid raw material and the powdery raw material may also be individually introduced into the mixer 40 to be mixed with the already swollen adhesive. Thereby, the first liquid raw material and the powdery raw material are individually mixed, thereby mixing the raw materials more uniformly. In this case, the second step may include introducing the first liquid raw material into the mixer 40 to be mixed with the already swollen adhesive before the powdery raw material. Thereby, the powdery raw material is introduced and mixed with the already swollen adhesive and the first liquid raw material, thereby preventing the powdery raw material from caking and mixing the raw materials more uniformly.

[0128] Instead of step S504 and step S505, Figure 5 The shown production method may include a step of extruding the raw materials mixed in the second step (step S502) through an extruder 50, and a step of forming the raw materials extruded from the extruder 50 into a sheet by at least a pair of vertically opposed rollers. More specifically, the raw materials may be formed into a sheet in stages by three sets of calendering rollers (i.e., six rollers). Instead of step S504 and step S505, Figure 5 The shown production method may also include a step of extruding the raw materials mixed in the second step (step S502) through an extruder 50, and a step of forming the raw materials extruded from the extruder 50 into a sheet by passing them between two or more horizontally adjacent calendering rollers. More specifically, the raw materials may be formed into a sheet in stages by passing them through each of four horizontally adjacent calendering rollers.

[0129] The embodiments of the present invention have been described above. However, the present invention is not limited to those embodiments, and various modifications can be made within the scope of the technical concepts disclosed in the claims, the specification, and the drawings. In addition, any shape or material not directly stated in the specification or the drawings is also within the scope of the technical concept of the invention of the present application, provided that it exhibits the functions and effects of the invention of the present application.

[0130] List of Reference Numerals

[0131] 40: Mixer

[0132] 50: Extruder

[0133] 60: Die

Claims

1. A method for producing a reconstituted pressure-formed tobacco sheet, the method comprising: a first step of introducing two or more powdery raw materials containing at least tobacco into a mixer and mixing them therein; a second step, after the first step, of introducing a first liquid raw material into the mixer and mixing it with the two or more powdery raw materials; and a forming step of forming the raw materials mixed in the second step into a pressure-formed sheet.

2. The method for producing a reconstituted pressure-formed tobacco sheet according to claim 1, Among them, wherein the two or more powdery raw materials contain tobacco, a binder, and an additive.

3. The method for producing a reconstituted pressure-formed tobacco sheet according to claim 1 or 2, Among them, wherein the first liquid raw material contains an aerosol source, water, and an additive.

4. The method for producing a reconstituted pressure-formed tobacco sheet according to claim 3, Among them, wherein the second step includes introducing the first liquid raw material formed by premixing the aerosol source, water, and an additive into the mixer.

5. The method for producing a reconstituted pressure-formed tobacco sheet according to any one of claims 1 to 4, which includes: a step of feeding the raw materials mixed in the second step into an extruder; and a step of further adding a second liquid raw material to the raw materials fed into the extruder.

6. The method for producing a reconstituted pressure-formed tobacco sheet according to claim 5, Among them, wherein the second liquid raw material contains water.

7. The method for producing a reconstituted pressure-formed tobacco sheet according to any one of claims 1 to 6, Among them, wherein the forming step includes: a step of extruding the raw materials mixed in the second step into a mold through an extruder; and a step of extruding the raw materials from the mold into a sheet form.

8. The method for producing a reconstituted pressure-formed tobacco sheet according to any one of claims 1 to 6, Among them, wherein the forming step includes: a step of extruding the raw materials mixed in the second step through an extruder; and a step of forming the raw materials extruded from the extruder into a sheet by at least a pair of vertically opposed rollers.

9. The method for producing a reconstituted pressure-formed tobacco sheet according to any one of claims 1 to 6, Among them, wherein the forming step includes: a step of extruding the raw materials mixed in the second step through an extruder; and a step of forming the raw materials extruded from the extruder into a sheet by passing them between two or more horizontally adjacent rollers.

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