Oral pouched product dosing device and method

Abstract

A dosing device 100 and method are disclosed for use in the manufacture of a pouched product containing a dose of powdered material P and an object, such as a capsule C. The powdered material and the object are supplied to an interior volume of a partially-formed pouch formed by a substantially continuous pouch material, prior to final sealing of the pouch material and creation of the pouched product. A powder supply channel 120 of the dosing device receives the powdered material prior to combination with the object. The object is held in a delivery position by an object delivery device 130 in the powder supply channel 120 for collection by the powdered material as the powdered material moves past the delivery position towards the partially-formed pouch.

Description

Technical Field

[0001] The present disclosure relates to a dosing device for use in the manufacture of a pouched product for oral use containing a dose of powdered material and an object such as a capsule. A method of manufacturing a pouched product containing a dose of powdered material and an object, such as a capsule, is also disclosed.Background

[0002] Oral tobacco products containing nicotine have been available for many years. Conventional formats for so-called "smokeless" tobacco products include moist snuff, snus, and chewing tobacco, which are typically formed of particulate, granular, or shredded tobacco, and which are either portioned by the user or presented to the user in individual portions, such as in single-use pouches or sachets. In addition, traditional tobacco materials and non-tobacco materials have been combined with other ingredients to form product formats distinct from traditional smokeless products, with example formats including lozenges, pastilles, gels, and the like.

[0003] Other oral products may contain flavourants and / or active ingredients such as nicotine, caffeine, botanicals, or cannabidiol. The format of such products can vary, and include pouched products containing a powdered or granular composition, lozenges, pastilles, liquids, gels, emulsions, meltable compositions, and the like. Oral pouched products may contain a powdered or granular composition together with an object such as a bead or capsule which may release additional flavourants or active ingredients, possibly over time, to enhance the user's experience.

[0004] The present invention relates to the manufacture of oral pouched products containing a powdered or granular composition together with an object. Such products are typically formed by supplying a web of pouch material (typically a water-permeable nonwoven material) to a dosing device, which includes a supply channel or tube around which a continuous tube of pouch material is formed. The leading end of the continuous tube is sealed beyond the end of the supply channel, at which point the internal contents of the product (i.e. the powder dose and capsule) are supplied to the interior of the tube and come to rest adjacent the interior of the sealed leading end. The trailing end of the pouch can then be sealed and separated from the continuous tube to form a discrete pouched product containing the powder dose and the object. Simultaneously, the new leading end of the continuous tube is sealed beyond the end of the supply channel and the process is repeated to form the next pouched product.

[0005] In prior art processes, the capsule is combined with the powder dose at the start of the process, so that the powder and capsule travel together until they reach the partially-formed pouch. The following problems may occur in prior art processes: capsule damage from e.g. heat, abrasion, impact or crushing; capsule insertion failure.

[0006] The present invention is intended to provide an improved manufacturing process which may, at least in some embodiments, address the above problems and provide additional advantages.Summary of the Invention

[0007] In a first aspect of the present invention, there is provided a dosing device for use in the manufacture of a pouched product containing a dose of powdered material and an object, wherein the dosing device is configured to supply the powdered material and the object to an interior volume of a partially-formed pouch formed by a substantially continuous pouch material, prior to final sealing of the pouch material and creation of the pouched product, wherein the dosing device comprises: a powder supply channel for receiving the dose of powdered material prior to combination with the object and for supplying the powdered material and the object to the interior volume of the partially-formed pouch; and an object delivery device configured to hold the object in a delivery position in the powder supply channel for collection by the powdered material as the dose moves past the delivery position towards the interior volume of the partially-formed pouch.

[0008] In some embodiments, the object delivery device is configured to receive an object in a loading position external to the powder supply channel and to move the object to the delivery position inside the powder supply channel. The object delivery device may move the object from the loading position to the delivery position in a linear direction. Alternatively, the object delivery device may move the object from the loading position to the delivery position in a circular or rotational direction. The object delivery device may comprise a rotating disc.

[0009] In some embodiments, the object delivery device comprises a chamber for receiving the object which moves from the loading position to the delivery position. The object delivery device may comprise a plurality of chambers, each for receiving an object.

[0010] In some embodiments, the object may be held in the delivery position (e.g. while in the chamber) by means of vacuum. The vacuum may be released as the powdered material reaches the delivery position.

[0011] In other embodiments, the object may be held in the chamber by an interference fit. The level of interference may be set such that the momentum of the passing powder frees the object from the interference fit.

[0012] In other embodiments, the object may be held in the chamber by a retaining means such as a rail. The retaining means may be released as the powdered material reaches the delivery position, or the momentum of the passing powder may free the object from the retaining means.

[0013] The powder supply channel may remain partially open with an object present in the delivery position. This is to maintain an air path through the object delivery device in the powder supply channel so that the powdered material dose can pass through the object delivery device and collect the object as it passes.

[0014] In some embodiments, the powdered material is supplied to the powder supply channel by means of air pressure. The air pressure may be positive or negative relative to atmospheric pressure, i.e. a positive pressure at the inlet end of the powder supply channel would push the powdered material through the channel and a negative pressure, i.e. a vacuum or partial vacuum at the outlet end of the powder supply channel would pull the powdered material through the channel.

[0015] In a second aspect of the invention, there is provided a method of manufacturing a pouched product containing a dose of powdered material and an object, comprising: supplying the powdered material to a powder supply channel of a dosing device, the powder supply channel being configured to receive the powdered material prior to combination with the object and to supply the powdered material and the object to an interior volume of a partially-formed pouch formed by a substantially continuous pouch material, holding the object in a delivery position in the powder supply channel for collection by the powdered material as the powdered material moves past the delivery position towards the partially-formed pouch, supplying the powdered material and the object to the interior volume of the partially-formed pouch, and sealing the pouch material to create the pouched product.

[0016] The method may further comprise receiving an object in a loading position external to the powder supply channel and moving the object to the delivery position inside the powder supply channel. The object may move from the loading position to the delivery position in a linear direction. Alternatively, the object may move from the loading position to the delivery position in a circular or rotational direction.

[0017] The object may be held in the delivery position by means of vacuum. The method may further comprise releasing the vacuum as the powdered material reaches the delivery position. As discussed above, the powdered material may be supplied to the powder supply channel by means of air pressure.

[0018] At least in preferred embodiments, the powder dosing and capsule insertion are separate processes and the powder and capsule are combined only at the last stage, prior to insertion in the partially-formed pouch. The invention provides more reliable and controllable combination of the powder and capsule. Risk of damage to the capsule may be reduced. The position of the capsule within the powder dose may be controlled, which may prevent damage to the capsule (e.g. heat damage, crushing) in the pouch sealing process. The powder may protect the capsule from damage.

[0019] The present disclosure generally relates to products configured for oral use. The term "configured for oral use" means that the product is provided in a form such that during use, saliva in the mouth of the user causes one or more of the components of the mixture (e.g., flavouring agents and / or active ingredients) to pass into the mouth of the user. In certain embodiments, the composition is adapted to deliver components to a user through mucous membranes in the user's mouth, the user's digestive system, or both, and, in some instances, said component is a nicotine component or an active ingredient (including, but not limited to, for example, nicotine, a stimulant, vitamin, amino acid, botanical, or a combination thereof) that can be absorbed through the mucous membranes in the mouth or absorbed through the digestive tract when the product is used.

[0020] The products relevant to the invention are pouched products, e.g., in the form of a mixture of one or more components (also referred to as a "particulate composition"), disposed within a moisture-permeable container (e.g., a water-permeable pouch). Pouched products generally comprise, in addition to the pouch-based exterior, a composition / mixture within the pouch that typically comprises one or more active ingredients and / or one or more flavourants, and various other optional ingredients. According to the present disclosure, such composition / mixture further comprises one or more objects, which includes capsules.

[0021] In some embodiments, the composition / mixture can comprise any filling composition, including those included within conventional pouched products, and further comprising one or more capsules. Such particulate compositions are generally mixtures of two or more components and as such, the compositions are, in some cases, referenced below as a "mixture."

[0022] Such mixtures in the water-permeable pouch format are typically used by placing a pouch containing the mixture in the mouth of a human subject / user. Generally, the pouch is placed somewhere in the oral cavity of the user, for example under the lips, in the same way as moist snuff products are generally used. The pouch preferably is not chewed or swallowed. However, in some embodiments, chewing may be advantageous, e.g., to rupture the capsule. Exposure to saliva causes some of the components of the mixture within the water-permeable pouch (e.g., flavouring agents and / or active agents) to pass through e.g., the water-permeable pouch and provide the user with flavour and satisfaction, and the user is not required to spit out any portion of the mixture. After about 10 minutes to about 60 minutes, typically about 15 minutes to about 45 minutes, of use / enjoyment, substantial amounts of the mixture have been ingested by the human subject, and the pouch may be removed from the mouth of the consumer for disposal. Preferred pouch materials for products described may be designed and manufactured such that under conditions of normal use, a significant amount of the contents of the formulation within the pouch permeate through the pouch material prior to the time that the pouch undergoes loss of its physical integrity.

[0023] Objects that can be included in the pouched product include capsules. Capsules generally comprise an internal payload ("filling") component and a capsule wall. The capsules can have any range of shapes, such as generally rectilinear, oblong, elliptical, oval or spherical shapes.

[0024] The capsule wall is generally formed of a material that is configured to allow for dispersement of the internal payload under desired conditions. For example, the capsule wall may comprise a material that is configured to dissolve or otherwise degrade under mouth conditions. As another example, the capsule wall may comprise a material that is configured to be broken or otherwise degraded by shear forces (e.g. chewing). The crush strength of suitable capsules can be sufficient to allow for normal handling and storage without significant degree of premature or undesirable breakage. Providing capsules that possess both suitable integrity during storage and the ability to rupture or otherwise break down at the time of use can be determined by experimentation, depending upon factors such as capsule size and type, and is a matter of design choice.

[0025] The composition of the capsule wall may vary depending upon the nature of the internal payload. For example, where internal payload is particulate or comprises a non-aqueous liquid, the capsule wall can comprise, e.g., a material such as wax, gelatin, cyclodextrin, or alginate. Classes of materials that can typically be used to form the capsule wall include, but are not limited to, proteins, polysaccharides, starches, waxes, fats, natural and synthetic polymers, and resins. In some embodiments, the composition of the capsule wall is selected so as to accommodate an aqueous internal payload therein. In this case, the composition of capsule wall must be selected so as to be at least partially resistant to water, e.g., so as to retain a water-containing payload therein without any substantial degradation for a period of time.

[0026] The composition of the internal payload component can vary. As referenced above, the payload can comprise a particulate material, including a powder payload, a non-aqueous (e.g., organic) liquid, and / or an aqueous (i.e., water-containing) liquid. Liquid-containing payloads can comprise, e.g., neat liquids, solutions, emulsions, or dispersions. In some embodiments, capsules are provided which comprise, as payload, an organic liquid such as an alcohol or oil. In some embodiments, capsules are provided which comprise, as payload, water. In further embodiments, payload can comprise a mixture of water and a miscible liquid, such as alcohol or glycerin. Liquid-containing payloads can comprise the liquid(s) alone or can comprise one or more additional components / additives. For example, in some embodiments, the internal payload comprises one or more release-modifying agents; one or more flavourants, one or more active ingredients, or any combination of two or more thereof. For example, in some embodiments, payload comprises a flavourant (e.g., menthol).

[0027] Certain specific examples of capsules include, but are not limited to, a capsule comprising a menthol-containing payload within a gelatin capsule wall. The capsules can be formed using any encapsulating technology known in the art.

[0028] The particulate composition may comprise one or more filler components. Such particulate filler components may fulfill multiple functions, such as enhancing certain organoleptic properties such as texture and mouthfeel, enhancing cohesiveness or compressibility of the product, and the like. Generally, filler components are porous, particulate materials and are cellulose-based. For example, suitable particulate filler components are any non-tobacco plant material or derivative thereof, including cellulose materials derived from such sources.

[0029] The particulate composition may comprise one or more flavouring agents. As noted above, in some embodiments, the particulate composition comprises a capsule wherein the payload comprises one or more flavouring agents. In some such embodiments, the one or more flavouring agents within the capsule are the only flavouring agents within the particulate composition. In other embodiments, the particulate composition further comprises one or more additional flavourants (wherein the one or more additional flavourants (in non-encapsulated form) can be the same as or different than the one or more flavourants within payload of the capsule). In other embodiments, the capsule within a given particulate composition do not comprise a flavourant; in such embodiments, the particulate composition typically comprises one or more non-encapsulated flavourants.

[0030] As used herein, a "flavouring agent" or "flavourant" is any flavourful or aromatic substance capable of altering the sensory characteristics associated with the oral product. Examples of sensory characteristics that can be modified by the flavouring agent include taste, mouthfeel, moistness, coolness / heat, and / or fragrance / aroma. Flavouring agents may be natural or synthetic, and the character of the flavours imparted thereby may be described, without limitation, as fresh, sweet, herbal, confectionary, floral, fruity, or spicy.

[0031] The particulate composition may comprise one or more of the following additional components: taste modifiers, salt, sweetener, binding agent, humectant, processing aid, buffering agent, oral care ingredient, colorant, active ingredient (e.g. botanical, stimulant, amino acid, vitamin, antioxidant, nicotine component, organic acid, cannabinoid, terpene, pharmaceutical ingredient), tobacco material.

[0032] In various embodiments, a moisture-permeable packet or pouch can act as a container for use of the composition within. For example, the pouch provides a liquid-permeable container of a type that may be considered to be similar in character to the mesh-like type of material that is used for the construction of a tea bag. If desired, flavouring ingredients, disintegration aids, and other desired components, may be incorporated within, or applied to, the pouch material. Suitable packets, pouches or containers may be of the type used for the manufacture of smokeless tobacco products.

[0033] The pouch can be formed from a fleece material, e.g. a fibrous nonwoven web. A "fleece material" may be formed from various types of fibers (e.g., cellulosic fibers; such as viscose fibers, regenerated cellulose fibers, cellulose fibers, and wood pulps; cotton fibers; other natural fibers; or polymer / synthetic-type fibers) capable of being formed into a traditional fleece fabric or other traditional pouch material. For example, a fleece material may be provided in the form of a woven or nonwoven fabric.

[0034] The pouch material may not dissolve under conditions of normal use (i.e. upon contact with saliva in the mouth of a user). In some embodiments, the pouch material can be dissolvable (i.e. orally ingestible) such that upon contact with saliva in the mouth of a user, the pouch material dissolves. Preferably, the pouch material will dissolve after a significant amount of the soluble components of the composition within the pouch (e.g., active ingredient(s) and / or flavourant(s)) permeate through the pouch material into the mouth of the user. For example, the pouch material can be configured to dissolve at a rate such that the pouch material holds the composition together for a period of time sufficient to allow for the release of substantially all water soluble components.Brief Description of the Drawings

[0035] An embodiment of the invention will now be described by way of example only and with reference to the accompanying drawings, in which: Fig. 1 shows a pouched product for oral use; Fig. 2 shows a schematic view of an embodiment of a dosing device in accordance with the invention; and Fig. 3 shows an object delivery device for use in the embodiment of Fig. 2. Detailed Description

[0036] Fig. 1 shows a pouched product 10 for oral use which contains a dose of powder and a capsule. The pouch is formed from a web of water-permeable nonwoven material 11 which is formed into a continuous tube by wrapping the web around a supply channel (shown in Fig. 2) and forming a longitudinal seal 12. The leading end 13 of the tube is sealed by a saw-tooth cut / seal 14. After the powder dose and capsule are added to the interior of the tube adjacent the leading end, the trailing end 15 of the pouch is sealed and separated from the continuous tube by forming a further saw-tooth cut / seal 16 to form a discrete pouched product containing the powder dose and the capsule.

[0037] Fig. 2 shows a schematic view of an embodiment of a dosing device 100 in accordance with the invention. Dosing device 100 includes a powder supply channel 120 for receiving the dose of powdered material P prior to combination with the capsule C and for supplying the combined powdered material and capsule to the interior volume of a partially-formed pouch.

[0038] A substantially continuous tube of nonwoven material 111 is formed around the downstream end of the powder supply channel 120. The leading end 113 of the tube has been sealed and a dose of powder P1 and capsule C1 are present in the interior of the tube adjacent the leading end 113. A further combined cut / seal is about to be formed behind the powder and capsule to form the trailing end of the pouch and thereby the discrete pouched product. This also forms a new leading end seal for the next pouch.

[0039] At the upstream end of the powder supply channel, the object delivery device 130 comprises a rotating disc 131 with a plurality of chambers 132 each configured to receive and hold a capsule C. In this embodiment, the capsules are retained in the chambers 132 by vacuum, shown by the arrow V, but as discussed above, other methods of retaining the capsules in position are possible. The disc 131 receives a capsule C2 in a loading position, external to the powder supply channel 120, and rotates to move the capsule to the delivery position at C3, inside the powder supply channel 120. Disc 131 effectively forms a magazine of capsules pre-loaded for sequential supply to the delivery position.

[0040] With the capsule C3 held in the delivery position, a dose of powdered material P2 is propelled into and along the powder supply channel 120. When the powder reaches the delivery position, or slightly prior to this, the vacuum holding capsule C3 is released and the capsule C3 is collected by the powder dose to travel along with the powder to the downstream end of the powder supply channel 120 and into the partially-formed pouch.

[0041] Fig. 3 shows a part-sectional view of an object delivery device for use in the embodiment of Fig. 2, comprising disc 131 with a plurality of chambers 132. One of the chambers is in the delivery position, aligned with the powder supply channel 120.

Claims

1. A dosing device for use in the manufacture of a pouched product containing a dose of powdered material and an object, wherein the dosing device is configured to supply the powdered material and the object to an interior volume of a partially-formed pouch formed by a substantially continuous pouch material, prior to final sealing of the pouch material and creation of the pouched product, wherein the dosing device comprises: a powder supply channel for receiving the dose of powdered material prior to combination with the object and for supplying the powdered material and the object to the interior volume of the partially-formed pouch; and an object delivery device configured to hold the object in a delivery position in the powder supply channel for collection by the powdered material as the dose moves past the delivery position towards the interior volume of the partially-formed pouch.

2. The dosing device of claim 1, wherein the object delivery device is configured to receive an object in a loading position external to the powder supply channel and to move the object to the delivery position inside the powder supply channel.

3. The dosing device of claim 2, wherein the object delivery device moves the object from the loading position to the delivery position in a linear direction.

4. The dosing device of claim 2, wherein the object delivery device moves the object from the loading position to the delivery position in a circular or rotational direction.

5. The dosing device of any of claims 2, 3 or 4, wherein the object delivery device comprises a chamber for receiving the object which moves from the loading position to the delivery position.

6. The dosing device of claim 5, wherein the object delivery device comprises a plurality of chambers, each for receiving an object.

7. The dosing device of claim 5 or 6, wherein the object is held in the chamber by means of vacuum.

8. The dosing device of claim 7, wherein the vacuum is released as the powdered material reaches the delivery position.

9. The dosing device of claim 5 or 6, wherein the object is held in the chamber by an interference fit.

10. The dosing device of claim 5 or 6, wherein the object is held in the chamber by a retaining means such as a rail.

11. The dosing device of any of claims 4 to 10, wherein the object delivery device comprises a rotating disc.

12. The dosing device of any of claims 1 to 11, wherein the powder supply channel remains partially open with an object present in the delivery position.

13. The dosing device of any of claims 1 to 11, wherein the powdered material is supplied to the powder supply channel by means of air pressure.

14. A method of manufacturing a pouched product containing a dose of powdered material and an object, comprising: supplying the powdered material to a powder supply channel of a dosing device, the powder supply channel being configured to receive the powdered material prior to combination with the object and to supply the powdered material and the object to an interior volume of a partially-formed pouch formed by a substantially continuous pouch material, holding the object in a delivery position in the powder supply channel for collection by the powdered material as the powdered material moves past the delivery position towards the partially-formed pouch, supplying the powdered material and the object to the interior volume of the partially-formed pouch, and sealing the pouch material to create the pouched product.

15. The method of claim 14, further comprising receiving an object in a loading position external to the powder supply channel and moving the object to the delivery position inside the powder supply channel.

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