Method of manufacturing non-continuous clove blend material and non-continuous clove blend material

Abstract

A non-continuous clove blend material comprising clove stem material and its method of manufacture are disclosed. Also provided are a component, a product, and a smoking article comprising said non-continuous clove blend material.

Description

[0001] METHOD OF MANUFACTURING NON-CONTINUOUS CLOVE BLEND MATERIAL AND NON-CONTINUOUS CLOVE BLEND MATERIAL

[0002] Technical Field

[0003] The present disclosure relates to a method of manufacturing a non-continuous clove blend material comprising clove stem material, and to a component, a product and a smoking article comprising said non-continuous clove blend material.

[0004] Background

[0005] Products that include blends comprising clove plant material are popular in some regions. For example, clove bud material may be used in tobacco industry products in a blend known as Kretek. Clove bud material is predominantly used in the manufacture of such products due to the high level of flavourant and aromatic compounds, such as eugenol and caiyophyllene, that is present in clove buds. Clove stem material is generated from the diying process and commonly treated as a by-product.

[0006] The present disclosure is based on the finding that a non-continuous clove blend material may be manufactured from clove stem material, thereby providing environmental advantages and commercial efficiencies in the use of this waste product. Summary

[0007] According to a first aspect of the present disclosure, there is provided a method of manufacturing non-continuous clove blend material, the method comprising: providing pre-sized particulate clove stem material having a Dpgo particle size of less than 2mm; producing an initial material, wherein the initial material comprises at least 5%, by mass, of the clove stem material; and, processing the initial material by subjecting the initial material to an increased mechanical pressure to thereby produce the non-continuous clove blend material. The initial material may comprise at least 35%, by mass, of clove stem material.

[0008] The initial material may comprise between 50% and 70%, by mass, of clove stem material. Providing pre-sized particulate clove stem material may comprise: separating clove stem material from other parts of the clove plant, including removing clove bud material; reducing the size of the clove stem material; and selecting particulate clove stem material having a particle size of less than 2mm.

[0009] The pre-sized particulate clove stem material may comprise:

[0010] (a) at least 50%, by mass, of material having a particle size less than 0.5mm; and / or

[0011] (b) 10-25%, by mass, of material having a particle size greater than 0.5mm and smaller than 2mm.

[0012] Processing the initial material may comprise the use of a water flow rate of 14-16 L / h.

[0013] The method may comprise processing the initial material by: setting the initial material to a predefined increased moisture content; subjecting the initial material to an increase in temperature; and subjecting the initial material an increased pressure.

[0014] Processing the initial material may comprise pressurising the initial material to a pressure in the range of 40-50 bar.

[0015] The method may further comprise feeding the processed material through a shearing gap, wherein the shearing gap is arranged between shearing surfaces, wherein a rotatable shearing member comprises one of the shearing surfaces, and wherein the method comprises rotating the shearing member at an angular velocity of 500-850 rpm.

[0016] The method may further comprise: providing pre-sized tobacco material having a Dpgo particle size of less 3 mm and a Dpso particle size of less than 2 mm; producing the initial material by combining the particulate clove stem material and the tobacco material; and, processing the initial material by subjecting the initial material to an increased mechanical pressure to bind the clove stem material and the tobacco material to thereby produce the non-continuous clove blend material. Thus, the method may be a method of manufacturing non-continuous clove blend material, the method comprising: providing pre-sized particulate clove stem material having a Dpgo particle size of less than 2mm; providing pre-sized tobacco material, having a Dpgo particle size of less 3 mm and a Dpso particle size of less than 2 mm; combining the particulate clove stem material and tobacco material to provide an initial material, wherein the initial material comprises at least 5%, by mass, of clove stem material; and, processing the initial material by subjecting the initial material to an increased mechanical pressure to bind the clove stem material and the tobacco material to thereby produce the non-continuous clove blend material.

[0017] The pre-sized tobacco material may comprise tobacco stem material. The pre-sized tobacco material may comprise at least 50%, at least 60%, at least 70%, at least 80%, or at least 90% tobacco stem material. The pre-sized tobacco material may consist of tobacco stem material.

[0018] Providing pre-sized particulate clove stem material may comprise: separating clove stem material from other parts of the clove plant, including removing clove bud material; reducing the size of the clove stem material; and selecting particulate clove stem material having a particle size of less than 2mm. The method may comprise processing the initial material by: setting the initial material to a predefined increased moisture content; subjecting the initial material to an increase in temperature; and subjecting the initial material an increased pressure to bind the clove stem material and the tobacco material.

[0019] The initial material, and / or the non-continuous clove blend material, may comprise at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, or at least 50%, by mass, of clove stem material. Preferably, the initial material, and / or the non-continuous clove blend material, comprises at least 35%, by mass, of clove stem material. The initial material, and / or the non-continuous clove blend material may contain between 50% and 70%, by mass, of clove stem material.

[0020] The pre-sized particulate clove stem material may comprise at least 50%, preferably at least 80%, by mass, of material having a particle size smaller than 0.5mm.

[0021] The pre-sized particulate clove stem material may comprise 10-25%, preferably 15- 20%, by mass, of material having a particle size greater than 0.5mm and smaller than 2mm.

[0022] The pre-sized tobacco material may comprise less than 40%, preferably less than 35%, by mass, of material having a particle size less than 0.5mm.

[0023] The pre-sized tobacco material may comprise at least 60%, preferably at least 70%, by mass, of material having a particle size greater than 0.5mm and smaller than 2mm.

[0024] The pre-sized particulate clove stem material may be bound to the pre-sized tobacco material mechanically, without using any externally applied binding agents. In some embodiments, the pre-sized particulate clove stem material is bound by binding agents which occur naturally in or are inherent in the pre-sized particulate clove stem material and / or tobacco material.

[0025] The total amount of particulate clove stem material, tobacco material, and water in the initial material may comprise at least 95%, preferably at least 99%, by mass. The initial material may consist of particulate clove stem material, tobacco material, and water.

[0026] The non-continuous clove blend material preferably includes no other materials or additives in addition to substances naturally found in clove stem material and tobacco material.

[0027] The non-continuous clove blend material preferably includes no clove bud material.

[0028] Combining the particulate clove stem material and tobacco material to provide an initial material may comprise mixing the materials at less than 8rpm for at least too minutes, preferably less than 6rpm for at least 120 minutes. Processing the initial material may comprise the use of a water flow rate of 14-16 L / h, such as 16 L / h.

[0029] Processing the initial material may comprise pressurising the initial material to a pressure in the range of 40-50 bar.

[0030] The method may further comprise feeding the processed material through a shearing gap, wherein the shearing gap is arranged between shearing surfaces, wherein a rotatable shearing member comprises one of the shearing surfaces, and wherein the method comprises rotating the shearing member at an angular velocity of 500-850 rpm.

[0031] The non-continuous clove blend material may have a strand length wherein:

[0032] (a) at least 75% of the strands have a strand length of at least 20mm; and / or (b) at least 20% of the strands have a strand length of at least 40mm.

[0033] The non-continuous clove blend material may have a bulk density of 230 to 600 kg / m3, preferably 240 to 340 kg / m3. The non-continuous clove blend material may have a eugenol content of 0.8-2% on a dry weight basis.

[0034] The non-continuous clove blend material may have a moisture content of at least 16%. The non-continuous clove blend material may have a water content of at least 15%, measured using a Karl Fischer titrator.

[0035] The non-continuous clove blend material may have a filling power of greater than 32 cms / iog.

[0036] The non-continuous clove blend material may comprise an aerosol forming material in an amount of 5-30%, preferably 15-20%, by mass.

[0037] The aerosol forming material may comprise glycerol, propylene glycol, or a mixture of glycerol and propylene glycol. The non-continuous clove blend material may comprise an active substance.

[0038] The active substance may be selected from nutraceuticals, nootropics and psychoactives.

[0039] The active substance may comprise nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations, or one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical.

[0040] The active substance may comprise nicotine or a nicotine salt.

[0041] The non-continuous clove blend material may comprise nicotine in an amount of up to 3% by weight.

[0042] The non-continuous clove blend material may comprise an acid in an amount of 0.1-5% by weight of the non-continuous clove blend material.

[0043] The acid may comprise lactic acid, benzoic acid, citric acid, levulinic acid, 2- methylbutyric acid, and / or 2-methylvaleric acid.

[0044] The method may comprise applying the aerosol forming material and / or the active substance:

[0045] (a) to the initial material prior to or while subjecting the initial material to the increased mechanical pressure; and / or

[0046] (b) to the non-continuous clove blend material after subjecting the initial material to the increased mechanical pressure.

[0047] According to a second aspect of the present disclosure, there is provided a non- continuous clove blend material, wherein the material comprises at least 35%, by mass, of clove stem material.

[0048] The material may further comprise botanical material. The material may further comprise tobacco material. The material may further comprise tobacco material.

[0049] The material may further comprise an additive selected from:

[0050] (a) an aerosol forming material; and / or (b) an active substance.

[0051] The initial material, and / or the non-continuous clove blend material may comprise between 40% and 75%, by mass, of clove stem material, and preferably comprises between 50% and 70%, by mass, of clove stem material.

[0052] The initial material, and / or the non-continuous clove blend material preferably includes no other materials or additives in addition to substances naturally found in clove stem material and tobacco material. The initial material, and / or the non-continuous clove blend material preferably includes no binder in addition to substances naturally found in clove stem material and tobacco material.

[0053] The initial material, and / or the non-continuous clove blend material preferably includes no other cellulosic or botanical material in addition to clove stem material and tobacco material.

[0054] The initial material, and / or the non-continuous clove blend material preferably includes no other clove material in addition to clove stem material. In particular, the non-continuous clove blend material preferably includes no clove bud material, clove flower material, or clove leaf material.

[0055] The initial material, and / or the non-continuous clove blend material may consist of clove stem material, tobacco material, and water.

[0056] The initial material, and / or the non-continuous clove blend material may have a strand length wherein at least 75% or at least 80% of the strands have a strand length of at least 20mm. The initial material, and / or the non-continuous clove blend material may have a strand length wherein at least 20% or at least 30% of the strands have a strand length of at least 40mm. The initial material, and / or the non-continuous clove blend material may have a bulk density of 230 to 600 kg / ms, preferably 240 to 340 kg / m'1.

[0057] The initial material, and / or the non-continuous clove blend material may have an eugenol content of 0.8 -2%, such as 1-1.5%, on a diy weight basis.

[0058] The initial material, and / or the non-continuous clove blend material may have a moisture content of at least 16%, such as 17-19%.

[0059] The initial material, and / or the non-continuous clove blend material may have a water content of more than 15%, such as greater than 15% and less than 18%, measured using a Karl Fischer titrator.

[0060] The initial material, and / or the non-continuous clove blend material may have a filling power (also referred to as ‘filling value’ or ‘fill value’) of greater than 32 cm'1 / 10g, such as greater than 35 citf / 10g.

[0061] The initial material, and / or the non-continuous clove blend material may comprise an aerosol forming material. The aerosol forming material maybe present in an amount of 5-30% by mass, such as 10-25%, or 15-20%, by mass. The aerosol forming material may comprise glycerol, propylene glycol, or a mixture of glycerol and propylene glycol.

[0062] The initial material, and / or the non-continuous clove blend material may comprise nicotine. The nicotine may be present in an amount of up to 3%, such as about 0.5%, 1%, or 2%, by weight of the non-continuous clove blend material.

[0063] The initial material, and / or the non-continuous clove blend material may comprise an acid. The total amount of the acid may be from about 0.1% to about 5% by weight of the non-continuous clove blend material. The acid may be selected from the group consisting of lactic acid, benzoic acid, citric acid, 2-methylbutyric acid, and 2- methyl valeric acid. In some embodiments, the acid is lactic acid. According to a third aspect of the present disclosure, there is provided a non- continuous clove blend material produced, obtained, or obtainable by the method of the first aspect. According to a fourth aspect of the present disclosure, there is provided a component for a delivery system, wherein the component comprises non-continuous clove blend of the second or third aspects.

[0064] The component may be for an aerosol provision system.

[0065] The component may be combusted to generate an aerosol.

[0066] According to a fifth aspect of the present disclosure, there is provided a product comprising a component according to the fourth aspect.

[0067] The product may be a non-combustible aerosol provision system. The non-combustible aerosol provision system may be an aerosol generating material heating system, also known as a heat-not-burn system. The non-combustible aerosol provision system may be a tobacco heating system.

[0068] According to a sixth aspect of the present disclosure, there is provided an article for use in or as an aerosol provision system, the article comprising a component according to the fourth aspect. According to a seventh aspect of the present disclosure, there is provided the use of a non-continuous clove blend material of the second or third aspect in an aerosol provision system.

[0069] According to an eighth aspect of the present disclosure, there is provided an article for use in an aerosol provision system comprising a non-continuous clove blend material of the second or third aspect.

[0070] According to a ninth aspect of the present disclosure, there is provided a system comprising a non-continuous clove blend material of the second or third aspect, and a device arranged to heat the non-continuous aerosol-generating material and generate an aerosol from the non-continuous aerosol-generating material. Pre-sized particulate clove stem material

[0071] “Pre-sized” material refers to material that has been subjected to a size selection procedure, and thus, pre-sized material comprises or consists of material having a determined desired particle size distribution.

[0072] For example, dried clove stem material, that has previously been separated from other clove plant material, including in particular, clove bud material, may be re-sized to a desired size range, for example, using a grinder. Particles of the desired size range may then be selected for example, by sieving, such as using a sequential sieving process.

[0073] The pre-sized particulate clove stem material may comprise greater than 95%, by mass, of material having a particle size of less than 2mm. For example, the pre-sized particulate clove stem material may comprise greater than 97%, greater than 99%, or greater than 99.5%, by mass, of material having a particle size of less than 2mm.

[0074] Preferably, substantially all (such as 100%, by mass) of the pre-sized particulate clove stem material has a particle size of less than 2mm.

[0075] The pre-sized particulate clove stem material may comprise greater than 95%, by mass, of material having a particle size of less than imm. For example, the pre-sized particulate clove stem material may comprise greater than 97%, greater than 99%, or greater than 99.5%, by mass, of material having a particle size of less than imm.

[0076] Preferably, substantially all (such as 100%, by mass) of the pre-sized particulate clove stem material has a particle size of less than imm.

[0077] The pre-sized particulate clove stem material may comprise greater than 95%, by mass, of material having a particle size of less than 0.7mm. For example, the pre-sized particulate clove stem material may comprise greater than 97%, greater than 99%, or greater than 99.5%, by mass, of material having a particle size of less than 0.7mm. Preferably, substantially all (such as 100%, by mass) of the pre-sized particulate clove stem material has a particle size of less than 0.7mm.

[0078] The pre-sized particulate clove stem material may comprise greater than 50%, by mass, of material having a particle size of less than 0.5mm. For example, the pre-sized particulate clove stem material may comprise greater than 60%, greater than 70%, or greater than 80%, by mass, of material having a particle size of less than 0.5mm. Clove stem material having a particle size of less than 0.5mm may be referred to as “clove stem fines” material. Clove stem fines material may be finer than “tobacco fines” material, which is typically considered to refer to tobacco material having a particle size of less than imm.

[0079] Pre-sized tobacco material

[0080] Providing pre-sized tobacco material may comprise providing a starter stem material and reducing the particle size of the starter stem material, for example, using a hammer mill. Particles of the desired size range may then be selected for example, by sieving, such as using a sequential sieving process.

[0081] Pre-sized tobacco material may comprise greater than 95%, by mass, of material having a particle size of less than 2mm. For example, the pre-sized tobacco material may comprise greater than 97%, or greater than 99%, by mass, of material having a particle size of less than 2mm.

[0082] Pre -sized tobacco material may comprise between 60% and 90%, by mass, of material having a particle size of between 0.5mm and 2mm. For example, the pre-sized tobacco material may comprise between 65% and 85%, or between 70% and 80%, such as about 75%, by mass, of material having a particle size of between 0.5mm and 2mm.

[0083] Pre -sized tobacco material may comprise less than 40%, by mass, of material having a particle size of less than 0.5mm. The pre-sized tobacco material may comprise between 15% and 35%, between 20% and 30%, or between 23% and 27%, such as about 25%, by mass, of material having a particle size of less than 0.5mm.

[0084] Pre -sized tobacco material may have a Dpgo particle size of less than 2.9 mm, such as less than 2.8, 2.7, 2.6, 2.5, 2.4, 2.3, 2.2, 2.1 or 2 mm. The Dpgo value refers to the particle size value that 90% of the stem material, by mass, is smaller than. For instance, if the Dpgo value is 3 mm then 90% (by mass) of the pre-sized stem material has a particle size smaller than 3 mm.

[0085] Pre -sized tobacco material may have a Dpso particle size of less than 2 mm, such as less than 1.9, 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1 or 1 mm. The Dpso value refers to the particle size value that 50% of the stem material, by mass, is smaller than. For instance, if the Dpso value is 2 mm then 50% (by mass) of the pre-sized stem material has a particle size smaller than 2 mm.

[0086] The pre-sized tobacco material may have a Dpgo particle size of less than 2.5 mm and a Dpso particle size of between 0.7mm and 1.5mm.

[0087] Pre -sized tobacco material may have a Dpio particle size of at least too microns and, optionally, a Dpio particle size of at least 150, 200, 250, 300 or 350, 400 or 500 microns. The Dpio value refers to the particle size value that 10% of the stem material, by mass, is smaller than. For instance, if the Dpio value is 100 micrometres then 10%

[0088] (by mass) of the pre-sized stem material has a particle size smaller than 100 micrometres.

[0089] The initial material preferably does not include a significant quantity of tobacco fines materials. In some embodiments, however, tobacco fines material may be included in the initial material, and in such embodiments, the tobacco fines material may comprise, consist of, or consist essentially of, tobacco factory dust, such as material generated in the processing of tobacco, and / or material generated in the production of smoking articles. The tobacco fines material may comprise, consist of, or consist essentially of, material generated in the production of Kretek smoking articles. Tobacco fines material generated in the production of Kretek smoking articles may include clove bud material.

[0090] Composition of the initial material

[0091] The initial material comprises at least 5%, such as between 35% and 80%, by mass, of clove stem material.

[0092] Preferably, the initial material may comprise between 40% and 75% of clove stem material, more preferably between 50% and 70%, by mass, of clove stem material. The initial material may comprise particulate clove stem material and botanical material.

[0093] The initial material may comprise particulate clove stem material and tobacco material. The initial material may comprise particulate clove stem material and tobacco stem material. The initial material may comprise particulate clove stem material and tobacco material wherein the mean, medial, and / or modal average particle size of the particulate clove stem material is smaller than that of the tobacco material.

[0094] The initial material may further comprise exotic tobacco and / or botanical material other than tobacco or clove stem fines material.

[0095] The initial material may further comprise Kretek material, which may comprise exotic tobacco such as Rajangan and / or Krosok tobacco. For example, the initial material may comprise tobacco factory dust produced in the manufacture of Kretek smoking articles.

[0096] The method of producing the material may further comprise providing additional tobacco fines material, and combining the additional tobacco fines material with the particulate clove stem material and tobacco material to provide the initial material.

[0097] The method may further comprise providing tobacco winnowings, and combining the tobacco material, particulate clove stem material, and tobacco winnowings, to provide the initial material comprising at least 5%, preferably at least 35%, clove stem material (by mass).

[0098] The initial material may comprise between 5% and 20% winnowings, such as tobacco winnowings. For example, the initial material may comprise between 7% and 18%, between 8% and 15%, or between 9% and 12%, such as about 10%, by mass of winnowings such as tobacco winnowings.

[0099] In methods that further comprise providing additional clove stem and / or tobacco material, such as fines and / or winnowings, the final proportions and size distributions of the particles of clove stem material and tobacco material are within the same range limits set out above, and for example, the initial material comprises at least 5%, preferably at least 35%, by mass, of clove stem material.

[0100] Other product features

[0101] The non-continuous clove blend material may have a water content that is greater than the water content of a material produced by the same method but comprising tobacco or an exotic tobacco blend material, which is typically less than 15%. For example, the non-continuous clove blend material may have a water content of greater than 15%.

[0102] More particularly, when measured on the basis of oven volatiles (OV) (by detecting the difference in weight of volatiles before and after heating in oven), the non-continuous clove blend material may have a water content greater than 16%, or greater than 17%, such as 17-19%. In contrast, the water content of a material produced by the same method but comprising tobacco or an exotic tobacco blend material, is typically less than 15% when measured by this method.

[0103] Likewise, when measured by gas chromatography, the non-continuous clove blend material may have a water content greater than 15%. In contrast, the water content of a material produced by the same method but comprising tobacco or an exotic tobacco blend material, is typically less than 14% when measured by this method.

[0104] Due to the increased water content, the non-continuous clove blend material may have a fill value that is greater than the fill value of a material produced by the same method but comprising tobacco or an exotic tobacco blend material, which is typically in the range of 30-32 cm'1 / 10g. For example, the non-continuous clove blend material may have a fill value of greater than 35 citf / 10g, such as greater than 36, 37, or 38 cnD / iog.

[0105] Fill value may be calculated using the following equation:

[0106] Fill value [cm3 / 10g] = 0.1 x (Volume[cm3] / Mass [^])

[0107] At a measured moisture content of M%.

[0108] If necessary, the fill value may be corrected to a standard moisture content using the following equation:

[0109] FV0= ((FVx (100 - Mo) x (M / M0)°-8) / (100 - M) Where:

[0110] FV0= Fill value at moisture content Mo%

[0111] FV = Fill value determined at moisture content m%

[0112] Mo= Appropriate target moisture content (%)

[0113] M = Actual moisture content of test tobacco (%) 0.8 = constant (Grandpre, 1987) The advantageous increased fill value of the non-continuous clove blend material relative to that of a material produced by the same method but containing only tobacco or an exotic tobacco blend material is due to an increased flexibility of the disclosed non-continuous clove blend material, resulting in reduced brittleness, as a consequence of the increased moisture content of the material. As a result of the increased flexibility, strands are less prone to snapping, and as a result, the strand length distribution of the disclosed clove blend material is such that the strands of the material have an increased length relative to strands of a material produced by the same method from tobacco or an exotic tobacco blend material only (referred to as “tobacco-only material”).

[0114] For example, strands of the disclosed non-continuous clove blend material may have a strand length distribution wherein more than 30%, or more than 35%, of the strands have a length of greater than 4cm, whereas in contrast, strands of the corresponding tobacco-only material have a strand length distribution wherein less than 10% of the strands have a length of greater than 4cm. Correspondingly, strands of the disclosed non-continuous clove blend material may have a strand length distribution wherein less than 50%, or less than 45%, of the strands have a length of between 2cm and 4cm, whereas in contrast, strands of the corresponding tobacco-only material have a strand length distribution wherein more than 60% of the strands have a length of between 2cm and 4cm. Strands of the disclosed non-continuous clove blend material may have a strand length distribution wherein less than 20% of the strands have a length of less than 2cm, whereas in contrast, strands of the corresponding tobacco-only material have a strand length distribution wherein greater than 25% of the strands have a length of less than 2cm.

[0115] Strands of the disclosed non-continuous clove blend material may have a thickness of at least 0.7mm, whereas in contrast, strands of the corresponding tobacco-only material have a thickness of less than 0.6mm. The increased length and thickness of the strands of the disclosed non-continuous clove blend material results from the reduced brittleness of the material. These properties are responsible for the advantageous improvements in fill value.

[0116] The non-continuous clove blend material may have a eugenol content of greater than 0.8%, measured on a dry weight basis. For example, the non-continuous clove blend material may have a eugenol content of greater than 0.9%, 1.0%, 1.1%, 1.2%, 1.3%, or 1.35%, measured on a dry weight basis.

[0117] The non-continuous clove blend material may have a caiyophyllene content of greater than 0.08%, measured on a diy weight basis. For example, the non-continuous clove blend material may have a caryophyllene content of greater than 0.09%, 0.1%, 0.11%, 0.12%, or 0.13%, measured on a dry weight basis.

[0118] Processing parameters The non-continuous clove blend material may be formed from the pre-sized particulate clove stem material mechanically, without using any externally applied binding agents.

[0119] For example, the pre-sized particulate clove stem material may be bound to other botanical material, such as tobacco material, mechanically, without using any externally applied binding agents.

[0120] Processing the initial material may comprise conveying the initial material through a conveyor, wherein the conveyer is operated at a throughput of greater than too kg / hr. The conveyer can be operated at a throughput of greater than too kg / hr and, preferably, at least no kg / hr and, preferably, at least 115 or 120 kg / hr.

[0121] The conveyor may build up a mechanical pressure, and may comprise an extruder.

[0122] Processing the initial material may comprise feeding the material through a shearing gap such that the processed clove and optional further material (e.g. tobacco material) is defibrated by expansion, wherein the shearing gap is arranged between shearing surfaces, wherein a rotatable shearing member comprises one of the shearing surfaces, wherein the shearing member comprises at least 140 grooves and wherein the grooves each have a maximum width in the circumferential direction of the shearing member of between 0.7mm and imm.

[0123] Processing the initial material may comprise heating the initial material to a temperature in the range of 6o-t8o°C, such as too-i4O°C, or 110-130 °C. The increase in temperature may be obtained by applying external heat and / or is the result of creating mechanical pressure. The material to be processed may be processed by conveying it continuously. In some embodiments, the material to be processed is processed in batches. Processing the initial material may comprise pressurising the initial material to a pressure in the range of between 30 bar and 55 bar, such as between 40 bar and 50 bar. This pressure is much lower than that used in the production of a corresponding material comprising only tobacco, which is typically at least 60 bar, such as in the range of between 60 bar and 120 bar. The use of lower pressures advantageously provides cost savings in the manufacturing process, without loss of product performance.

[0124] The step of processing the initial material may comprise conveying the initial material through a conveyor which builds up a mechanical pressure. In some embodiments, pressurising the initial material to the pressure is performed before feeding the processed initial material through a shearing gap.

[0125] The conveyor may comprise an extruder. The conveyer may be operated at a throughput of less than 120 kg / hr, such as less than no kg / hr, or less than too kg / hr.

[0126] The method may further comprise exposing the processed initial material to a drop in pressure, resulting in flash evaporation.

[0127] The method may further comprise feeding the processed material through a shearing gap, such that the processed material is defibrated by expansion.

[0128] The shearing gap may have a width in the range of 10 to 2000 microns and, preferably, in the range of 50 to 300 microns.

[0129] The shearing gap may be arranged between shearing surfaces, wherein a rotatable shearing member comprises one of the shearing surfaces. The shearing member may comprise a plurality of grooves, such at least 80 grooves and, preferably, at least 90, too, 120, 140, 160 or 180 grooves. The grooves may each have a maximum width in the circumferential direction of the shearing member of between 0.3-2 mm, 0.5-1.5 mm, and preferably at least 0.7mm or at least 1 mm.

[0130] The method can comprise rotating the shearing member at an angular velocity of at least 10 rpm and, preferably, at least too rpm, 300 rpm, 300 rpm or 350 rpm. In some embodiments, the method comprises rotating the shearing member at an angular velocity of less than 700 rpm, less than 600 rpm, less than 500 rpm, and preferably less than 400 rpm. The use of shearing member rotation speed advantageously provides cost savings in the manufacturing process, without loss of product performance.

[0131] Heating the initial material to the increased temperature may be performed before feeding the initial material through a shearing gap.

[0132] Pressurising the initial material to the increased pressure may be performed before feeding the processed intial material through a shearing gap.

[0133] Component for delivery system The component of the fourth aspect comprises non-continuous clove blend material.

[0134] The non-continuous clove blend material may be produced by the method of the first aspect, and / or may be a material of the second and / or third aspect.

[0135] The component can further comprise a second material.

[0136] The second material may be a second clove blend material. The second material may be a non-continuous material containing no clove stem material, such as a non-continuous material produced from tobacco only. The second material may be a non-continuous material containing a substantially lower clove content than the present non- continuous clove blend material, such as a non-continuous material produced from tobacco comprising a Kretek blend.

[0137] The second material may comprise tobacco. For example, the second material may comprise a reconstituted tobacco material, or a cut-rag tobacco.

[0138] The second material may comprise a Kretek blend. The non-continuous clove blend material may be used in a blend in Kretek components, in a blend with Kretek material and / or other non-Kretek tobacco material.

[0139] The non-continuous clove blend material may also be used as a taste modifying agent in non-Kretek components.

[0140] The component may comprise the present non-continuous clove blend material and a second material in the form of a blend. The blend may comprise the non-continuous clove blend material in an amount of between 5% and 50% of the total material in the blend. For example, the blend may comprise the non-continuous clove blend material in an amount of between 10% and 40%, or between 15% and 30%, such as in an amount of about 12.5% or 25% of the total material in the blend.

[0141] The non-continuous clove blend material may be configured such that the inclusion of the non-continuous clove blend material results in, during use of the component, an increased eugenol delivery in comparison to an equivalent component that does not comprise the non-continuous clove blend material, or that comprises a non-continuous material containing only tobacco.

[0142] The non-continuous clove blend material may be configured such that the inclusion of the non-continuous clove blend material in a blend in the component results in, during use of the component, the delivery of 0.1 mg of eugenol for every 10% (by mass) inclusion of the non-continuous clove blend material in the blend.

[0143] Thus, the non-continuous clove blend material may advantageously be used in the production of a Kretek product, for example as a blend with tobacco and / or Kretek material, thus replacing at least a portion of the Kretek material used in a Kretek blend, without loss of product performance or flavour. In this way, the non-continuous clove blend materials is highly advantageous because it makes productive and economical use of waste material from the processing and manufacture of other clove products. Thus, waste clove stem material, produced in as a by-product in the manufacture of clove buds, that would otherwise be disposed of, can instead be recycled. Moreover, the increased fill value of the non-continuous clove blend material resulting from the extrusion process, provides further advantages because less of the material is required to provide the same filling capacity and product performance.

[0144] The non-continuous clove blend material also advantageously provides simple incorporation of clove flavour without requiring full Kretek implementation.

[0145] The component may comprise a tobacco rod for a combustible aerosol provision system. The component may be for an aerosol provision system. The component may be a tobacco rod for a cigarette, cigar or cigarillo.

[0146] The component maybe for a non-combustible aerosol provision system. Brief Description of the Drawings

[0147] Embodiments will now be described, by way of non-limiting example only, with reference to the drawings, in which:

[0148] FIG. 1 is a flow chart illustrating an embodiment of a method of processing clove stem material, and in this example also a further material such as a botanical material, for example comprising tobacco material, into a non-continuous clove blend material;

[0149] FIG. 2 is a schematic view of an embodiment of a pressure defibrating device;

[0150] FIG. 3 is a schematic view of a pressure conditioning and defibration system; and,

[0151] FIG. 4 is a schematic view of another embodiment of a pressure conditioning and defibration system.

[0152] Detailed Description

[0153] Referring to FIG. 1, a method for processing clove stem material and another material, such as a botanical material, for example comprising tobacco material, into a non- continuous clove blend material is shown.

[0154] The non-continuous clove blend material produced by the method may then be incorporated into a product. The product may be a component for a deliveiy system as described herein, for example, an aerosol provision system. In some embodiments, the aerosol provision system is a combustible aerosol provision system or a non-combustible aerosol provision system.

[0155] The component may be, for example, a rod of material. In one particular embodiment, the component is a rod of material for a cigarette or a tobacco heating system. The product may be an article as used in a combustible aerosol provision system, such as a cigarette, cigarillo, cigar, or tobacco for pipes or for roll-your-own or for make-your- own cigarettes. The product may alternatively be an article for use in or with a non-combustible aerosol provision system that releases compounds from an aerosol-generating material without combusting the aerosol-generating material, such as an electronic cigarette, a tobacco heating product, and hybrid systems to generate aerosol using a combination of aerosol-generating materials.

[0156] The product may alternatively be for use in or with an aerosol-free deliveiy system that delivers at least one substance to a user orally, nasally, transdermally or in another way without forming an aerosol, including but not limited to, lozenges, gums, patches, articles comprising inhalable powders, and oral products such as oral tobacco which includes snus or moist snuff, wherein the at least one substance may or may not comprise nicotine.

[0157] Material

[0158] ‘Clove’ and ‘clove stem material’ refers to any material derived from a plant from the species Syzygium aromaticum, which may be referred to as a ‘clove plant’ or ‘clove tree’.

[0159] Preferably, clove stem material for use in the disclosed process may be derived from the stem of the clove plant material, and such material may be referred to as ‘clove stem material’. Clove stem material does not include material derived from other parts of the clove flowerbuds, such as, in particular, clove bud material. Clove buds contain significantly higher levels of eugenol and other chemicals than other parts of the clove plant, including in particular, clove stem, which contains a relatively low level of eugenol in comparison to clove bud material. As a result of this, clove products, and in particular, clove-containing smoking articles, such as Kretek smoking articles, are produced from clove bud material in order to provide the highest possible levels of eugenol. Clove stem material is generated as a waste or by-product in the manufacture of these other clove products contain clove bud material. It has surprisingly and advantageously been found that, using the disclosed method and formulation, this byproduct clove stem material may be processed to form a high quality clove blend material despite the initial clove stem material containing only relatively low levels of eugenol. Thus, a significant advantage of the disclosed method is provided in the environmental and economic efficiencies obtained by the use of such clove stem material that would otherwise be discarded as waste, as a by-product of clove bud processing.

[0160] Clove material

[0161] “Clove” typically refers to the dried, unopened bud of a tropical tree belonging to the family of Myrtaceae. Clove type classification is based on the common types of clove that are found in Indonesia. They are Sikotok, Siputih and Zanzibar.

[0162] Sikotok clove has a pyramidal canopy. The leaf of sikotok is long, oblong and asymmetrical. The flower is thick and conical in shape narrowing in the middle. In terms of its clove bud, Sikotok is generally short and fat.

[0163] Siputih clove has an oblong canopy. The leaf of Siputih is long, oblong and asymmetrical which has conical shape flower. Siputih clove bud is typically similar to Sikotok but is longer in length.

[0164] Zanzibar clove has a conical canopy. The leaf of Zanzibar is long, oblong and symmetrical. The flower is slim and conical in shape. Zanzibar clove bud has a cylindrical thin and long shape. Clove may also be classified based on its origin. These classifications include; Manado, Toli-toli, Bali and Java, and each of these types provide different aroma and taste.

[0165] Dried Manado clove bud is thick and conical in shape narrowing in the middle. Dried Manado clove has Eugenol content of about 15%, Eugenol Acetate about 2.8%, and Beta-Caryophyllene about 2.4%. Manado clove is mostly grown in North Sulawesi, which is dominated by the Sikotok Type. In general, Toli-toli produced clove has a low sweet aroma. Dried Toli-toli clove is conical in shape. Toli-toli clove has Eugenol content of about 15%, Eugenol Acetate about 3.1%, and Beta-Caryophyllene about 2.4%. Toli-toli clove, which mostly grown in Central Sulawesi is dominated by Siputih, Sikotok and Zanzibar.

[0166] Java clove aroma is medium level. Java clove is dominated by Zanzibar type. Dried Java clove is in conical shape, which has Eugenol content of about 15.4%, Eugenol Acetate content about 3.2%, and Beta Caryophyllene about 2.5%.

[0167] Bali clove has an aroma that is medium to medium high. Similar to Java clove, Bali clove is also dominated by Zanzibar type. Dried Bali clove is conical in shape, which has Eugenol content about 15.8%, Eugenol acetate about 2.6% and Beta Caryohpyllene about 2.5%.

[0168] The clove tree, Syzygium aromaticum, is a conical evergreen having large oval leaves and crimson flowers in numerous groups of terminal clusters, typically from 15 to 50. The flower buds are initially a pale color and gradually become green, after which they develop into a reddish brown or bright red, when they are ready for collecting.

[0169] Cloves are harvested when i5-2omm long, and consist of a long calyx, terminating in four spreading sepals, and four unopened petals that form a small ball in the centre. The flower buds are strongly aromatic and impart a flavor that can be described as hot and pungent.

[0170] Clove stem material refers to material derived from the part of the clove tree which supports the cluster of clove flower. Clove stem is considered to be a waste material byproduct of clove bud production, and is not used further in commercial products due to having a veiy low aroma and taste. Clove stem is considered a contaminant in the production of clove products.

[0171] The skilled person would easily be able to distinguish between clove bud and clove stem material using any of a number of methods known in the art, including visual separation. Clove bud material may be used as the major component of kretek tobacco products. Clove contributes a unique hot and bitter taste and aroma in kretek blends and gives a crackling noise. The word kretek itself describes an indigenous Indonesian tobacco product containing tobacco, cloves, and flavouring. The name kretek is a shortened form of “kretek Strootje” which literally translated means “a little straw that crackles.”

[0172] Clove bud material used in the manufacture of kretek products may be from Manado, Toli-toli, Bali and Java clove. The production and quality of each of clove type are influenced by environmental conditions (including climatic, altitude, weather, and soil condition), agricultural practices, post-harvest handling and processing. These variables may have a significant effect on the physical characteristics of the clove material in terms of aroma, taste, colour, and chemical characteristics (in particular, content of eugenol, eugenol actetate, and beta-caryophyllene). Thus, a major problem faced by manufacturers of clove products is to maintain the consistency of taste and aroma. This problem is overcome by the method disclosed in the present application, which advantageously allows the production of material having highly consistent and reproducible flavour and aroma.

[0173] Clove stem material for use in the disclosed process does not comprise clove bud material and does not comprise clove leaf material.

[0174] The clove stem material may include, but is not limited to, the following type of clove stem material: Jawa, Bali, Manado, and / or Manado second grade. The use of clove stem material may provide a distinctive flavour and sensorial experience for the end user. Cloves are known to have sensory effects including aroma, spicy, numbing, crackling, and throat soothing features among others. The organoleptic properties of the non-continuous clove blend material produced by the disclosed method may thus provide improved flavour and sensorial properties over previous non- continuous materials.

[0175] Tobacco and Other Botanical Material

[0176] The non-continuous clove blend material may optionally comprise tobacco material, such as tobacco stem material. ‘Tobacco’ and ‘tobacco material’ refers to any material derived from a plant from the genus Nicotiana.

[0177] ‘Botanical material’ refers to any material derived from a plant. ‘Non-clove botanical material’ refers to any material derived from any plant that is not a plant from the species Syzygium aromaticum. Likewise, ‘non-tobacco botanical material’ refers to any material derived from any plant that is not a plant from the genus Nicotiana.

[0178] The non-continuous clove blend material may comprise botanical material in addition to clove stem material.

[0179] ‘Other botanical material’ refers to any material that is not tobacco material or clove stem material. Thus other botanical material is any material derived from any plant that is not a plant from the species Syzygium aromaticum or genus Nicotiana. Thus, other botanical material includes, but is not limited to, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemaiy, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, maijoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberiy, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. The mint may be chosen from the following mint varieties:

[0180] Mentha Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens.

[0181] ‘Exotic tobacco’ includes but is not limited to the following tobacco materials: Rajangan tobacco, which may be dark Rajangan tobacco or bright Rajangan tobacco, Krosok, Madura, Maesan, Weleri, Pakpie Ploso, Temanggung, KASTURI, Boyolali, and / or Ploso. The use of a blend of clove bud material and tobacco material as a material may be referred to as a ‘Kretek blend’, or ‘Kretek material’.

[0182] Kretek material may comprise clove bud material in an amount of 20-40%, such as 25- 31%, by mass.

[0183] Kretek material may comprise tobacco in an amount of 20-80%, such as about 69-75%, by mass. Kretek material may comprise exotic tobacco. For example, Kretek material may comprise exotic tobacco in an amount of 30-50%, such as about 40%, by mass.

[0184] Reconstituted tobacco materials comprising Kretek material may comprise clove processing dust. Clove processing dust is produced as a by-product during the processing of clove bud material. Clove processing dust does not include clove stem material.

[0185] In some embodiments, tobacco fines comprises, consists of, or essentially consists of tobacco factory dust.

[0186] ‘Tobacco factoiy dust’ refers to the fine dust that is generated as a by-product of tobacco processing and the manufacture of tobacco products such as cigarettes. Tobacco factory dust / tobacco dust generally has a particle size of less than 0.5 mm. In some embodiments, tobacco factoiy dust has a Dpso of 125 micrometres. This means that 50% of the tobacco dust particles, by mass, have a particle size that is smaller than 125 micrometres.

[0187] The fines material may comprise Kretek material, and thus may be referred to as ‘Kretek fines’ material. For example, the Kretek fines may comprise, consist of, or essentially consist of, factory dust produced during the manufacture of smoking articles comprising Kretek material.

[0188] The fines may comprise a Kretek blend. As an example, a mild Kretek blend may have the following composition: Rajangan tobacco (38% by mass), tobacco stem material (14% by mass), Krosok tobacco (4% by mass), FCV / Oriental tobacco (19% by mass), and clove bud material (25% by mass). As a further example, another Kretek blend may - 2. - have the following composition: Rajangan tobacco (30% by mass), tobacco stem material (11% by mass), Krosok tobacco (5% by mass), FCV / Oriental tobacco (23% by mass), and clove bud material (31% by mass). Generally, a Kretek blend may include (by mass) 30-38% Rajangan tobacco, 11-14% tobacco stem material, 4-5% Krosok tobacco, 19-23% FCV / Oriental tobacco, and 25-31% clove bud material.

[0189] In some embodiments, the fines material may comprise tobacco fines, Kretek fines, and clove stem fines. For example, the fines may comprise tobacco factory dust produced during the manufacture of smoking articles comprising tobacco material, Kretek factory dust material produced during the manufacture of smoking articles comprising Kretek material, and / or clove processing dust produced as a by-product during the processing of clove buds.

[0190] ‘Tobacco winnowings’ are coarsely cut stem particles, midrib or stalk, but can include some lamina and reconstituted sheet, which have been sorted and removed from already cut tobacco because they are conventionally considered to be undesirable in aerosol provision systems due to their size and shape and would impair the quality of the aerosol provision systems, for example, cigarettes. For this reason, conventionally winnowings are usually recycled or disposed of as a waste product.

[0191] Tobacco winnowings may refer to winnowings from cigarette production (CPP- winnowings=winnowings from cigarette production / packaging) or those from tobacco processing (TP-Winno wings). The term ‘winnowings’ hereinafter encompasses both winnowings from cigarette production and those for tobacco processing, unless otherwise stated.

[0192] Overview

[0193] FIG. 1 shows a flow chart illustrating one implementation of the disclosed method, which comprises processing clove stem material and a further material, such as a botanical material, in this example, comprising tobacco material, into a non-continuous clove blend material. The method may comprise the following steps:

[0194] Step (SiC) of providing a pre-sized particulate clove stem material, for example, that has a Dpgo particle size of less 2 mm;

[0195] Step (SoT) of conditioning tobacco material; Step (SiT) of providing a pre-sized tobacco material that has a Dpgo particle size of less than 3 mm and a Dpso particle size of less than 2 mm; Step (S2) of combining the pre-sized particulate clove stem material and pre-sized tobacco material to provide an initial material, wherein the initial material comprises at least 5%, preferably at least 35%, by mass, of clove stem material;

[0196] Step (S3) of processing the initial material by setting the initial material to a predefined increased moisture content, subjecting the initial material to an increase in temperature and subjecting the initial material an increased pressure in order to bind the clove stem material and the tobacco material;

[0197] Step (S4) of feeding the initial material through a shearing gap to form a non- continuous clove blend material; and Step (S5) of cooling the non-continuous clove blend material.

[0198] It should be recognised that in some embodiments (not shown), one or more of steps (S1C), (SoT), (S1T), (S2), (S3), (S4) and / or (S5) may be combined. For instance, the initial material may be conditioned whilst in the feeding apparatus, for example, being brought to initial conditions (such as, temperature, moisture and pressure) whilst travelling through a screw feeder of the feeding apparatus, or may be conditioned in the defibration device.

[0199] It should also be recognised that in some embodiments (not shown), one or more of steps (S1C), (SoT), (S1T), (S2), (S3), (S4) or (S5) may be in a different order or omitted entirely. For example, the tobacco material may be conditioned before or after being subjected to the pre-sizing step (S1T). However, in the present example the tobacco material is conditioned (SoT) before being subjected to the pre-sizing step (SiT). In step (SoT) the tobacco material is brought to one or more of the following initial conditions (values given for pressure are always above atmospheric pressure):

[0200] Temperature: 8o-i47[deg.] C., preferably ioo-i2o[deg.] C.

[0201] Moisture: in the range of 6-14%, preferably in the range of 8-12% Pressure (gas over-pressure): 0-8 bar, and preferably, 0-3 bar, and preferably, 0-1 bar.

[0202] This tobacco pre-conditioning may take place under atmospheric conditions.

[0203] Alternatively, in some embodiments the pre-conditioning process is operated at a pressure above atmospheric pressure, as described in patent specification DE 10304 629 Al. During pre-conditioning and / or simultaneously during the process (atmospheric or above atmospheric pressure), casing and flavouring agents may be added, in a manner known to those skilled in the art.

[0204] Preferably, at step (SoT) the tobacco material is brought to all of the above initial conditions.

[0205] The step (S3) of processing the initial material by setting the initial material to a predefined increased moisture content, subjecting the initial material to an increase in temperature and subjecting the initial material to an increased pressure in order to bind the clove stem material and the tobacco material is preferably operated on the basis of one or more of the following a parameters:

[0206] Temperature: 8o-i8o[deg.] C., preferably 125-156 [deg.] C.

[0207] Moisture: in the range of 15-50%, preferably in the range of 18-45%. Mechanical pressure: 80-250 bar, preferably 72-132 bar.

[0208] Preferably, step (S3) is operated on the basis of all of the above parameters for temperature, moisture and mechanical pressure. In other words, the material is brought to the above temperature, moisture and pressure values.

[0209] At step (S3), the initial material is subjected to an increased pressure, as explained above. At the step (S4) of feeding the initial material through a shearing gap to form a non-continuous tobacco material, this increased pressure drops again. This usually takes place on discharge from a processing apparatus (e.g. extruder, screw conveyor, piston-cylinder unit) that subjects the initial material to the increased temperature, pressure and moisture. The drop in pressure on discharge from this shearing gap results in a flash evaporation, thereby causing the material to expand. This advantageously increases the filling capacity of the material. At step (S3), the initial material is heated and placed under pressure to improve the flavour through chemically operated processes (e.g. Maillard reaction or caramelisation) and also to store energy to promote the by shearing and expansion through the shearing gap. The pressure generation and heating may be operated with standard plug screw feeders, the housings of which in particular may also be heated. In some embodiments, the step (S3) of processing the initial material and / or the step (S4) of feeding the initial material through the shearing gap to form a non-continuous clove blend material is performed using an apparatus of the configuration shown in Fig.

[0210] 3-

[0211] Step SiC - providing pre-sized particulate clove stem material

[0212] Pre-sized particulate clove stem material refers to clove stem material that has been subjected to a pre-sizing step prior to combining the clove stem material with the tobacco material to form the initial material.

[0213] The Dpgo particle size of the pre-sized particulate clove stem material is less 2 mm. The pre-sized particulate clove stem material may have a Dpgo particle size of less than 1.9 mm, such as less than 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1, 1, 0.9, 0.8, or 0.7 mm. The Dpgo value refers to the particle size value that 90% of the material, in this case, clove stem material, by mass, is smaller than. For instance, if the Dpgo value is 2 mm then 90% (by mass) of the pre-sized clove stem material has a particle size smaller than 2 mm. The Dpso particle size of the pre-sized particulate clove stem material is less 0.5 mm. The pre-sized particulate clove stem material may have a Dpso particle size of less than 0.4 mm, such as less than 0.3 or 0.2 mm.

[0214] The Dpso value refers to the particle size value that 50% of the material, in this case, clove stem material, by mass, is smaller than. For instance, if the Dpso value is 0.5 mm then 50% (by mass) of the pre-sized stem material has a particle size smaller than 0.5 mm.

[0215] Smaller Dpso and Dpgo values indicate smaller particle sizes and thus less separation of the pre-sized stem material from other constituents of the tobacco initial material and also fewer flakes in the produced non-continuous tobacco material.

[0216] The Dpio value refers to the particle size value that 10% of the material, in this case, clove stem material, by mass, is smaller than. For instance, if the Dpio value is too micrometres then 10% (by mass) of the pre-sized clove stem material has a particle size smaller than too micrometres. In some embodiments, the step (SiC) of providing the pre-sized particulate clove stem material comprises an initial step of feeding clove stem material, that has previously been separated from other clove plant parts, such as clove buds, to a particle size reduction device that is configured to reduce the size of the clove stem material.

[0217] The particle size reduction device may be a one or a combination of any suitable milling, cutting, shredding, grinding, threshing, etc device. In one embodiment, the size reduction device is a disc mill. A hammer mill may alternatively be used.

[0218] In some embodiments, the pre-sized clove stem material has a particle size of less than 2 mm. In one embodiment, the pre-sizing step comprises passing the clove stem material through a 2 mm sieve and discarding, or processing to reduce the size of, any material that does not pass through the sieve.

[0219] It has been found that pre-sizing the clove stem material to a Dpgo value of less than 2 mm improves the quality of the produced non-continuous clove blend material, including the organoleptic qualities of the component or product. In particular, this pre-sizing of the clove stem material has been found to advantageously improves the mixing process to provide improved homogeneity and reproducibility of the initial material and thereby the resulting non-continuous clove blend material. The pre-sizing of clove stem material to provide this particle size distribution has also been found to improve the material bonding during the production of the non-continuous clove blend material, thereby improving the quality and flexibility of the material, thus providing a material having a reduced density and increased filling power.

[0220] Step SiT - providing pre-sized tobacco material

[0221] Pre-sized tobacco material refers to tobacco material that has been subjected to a presizing step prior to combining the stem material with the clove stem material to form the initial material.

[0222] In some embodiments, the step of providing a pre-sized tobacco material comprises providing a material that has a Dpgo particle size of less than 3 mm and a Dpso particle size of less than 2 mm. Pre-sizing the stem material means that larger stem material, for example, long or mixed stem, can be utilised and processed to have a Dpgo particle size of less than 3 mm and a Dpso particle size of less than 2 mm, for instance a Dpgo particle size of less than 2.5mm and a Dpso particle size of between 0.7mm and 1.5mm. Thus, the process does not rely on the procurement of short stem.

[0223] Pre-sizing the tobacco material to provide a Dpgo particle size of less than 3 mm and a Dpso particle size of less than 2 mm and pre-sizing the clove stem material to have a Dpgo particle size of less 2 mm, a Dpso particle size of less than 0.5 mm, where at least 5%, by mass, of material having a particle size greater than 0.5 mm, has been found to provide a number of significant advantages. For example, providing this combination of clove stem and tobacco particle size ranges has advantageously been found to reduce the separation of the clove stem material and tobacco material once they have been mixed together and, for example, whilst disposed in a mixing silo.

[0224] In particular, pre-sizing the tobacco and clove stem material into these size ranges has been found to reduce separation and de-mixing of the materials in the mixing silo and thus results in a more consistently produced non-continuous material with a more consistent density.

[0225] In some embodiments, the pre-sized tobacco material has a Dpgo value of less than 2.9 mm and, for instance, a Dpgo value of less than 2.8, 2.7, 2.6, 2.5, 2.4, 2.3, 2.2, 2.1 or 2 mm. In some embodiments, the Dpgo value may be less than 1.9, 1.8, 1.7, 1.6 or 1.5 mm. In some embodiments, the pre-sized tobacco material has a Dpso value of less than 1.9 mm and, for instance, a Dpso value of less than 1.9, 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1 or 1 mm. In some embodiments, the pre-sized stem material has a Dpso value of less than 0.9 or 0.8 mm. The Dpso value can alternatively or in addition be greater than 0.5mm, 0.6mm or 0.7mm. In some embodiments, the Dpso value is between 0.7mm and 1.5mm.

[0226] Smaller Dpso and Dpgo values of the tobacco material indicate smaller particle sizes, and thus less separation of the pre-sized stem material from other constituents of the initial material. In some embodiments, the step (S1T) of pre-sizing the stem material results in a presized stem material that has Dpio value of at least too micrometres and, preferably, a Dpio value of at least 150, 200, 250, 300 or 350 micrometres. In some embodiments, the Dpio value may even be at least 400 or 500 micrometres. Higher Dpio values indicate reduced amounts of fine dust, and thus lower densities of the produced non- continuous material, meaning that less is extracted as winnowings.

[0227] It has also been found that such pre-sizing of the tobacco material means that the pressure defibration device can be operated at a higher throughput such that a greater amount of non-continuous material can be produced per hour. The manufacture of the non-continuous material will also be more repeatable and consistent. In some embodiments, the pressure defibration device is run at a throughput of at least 100 kg / hr and, preferably, at least 110, 115 or 120 kg / hr. In some embodiments, the step (SiT) of providing the pre-sized tobacco material comprises providing stem material and feeding the stem material to a particle size reduction device that is configured to reduce the size of the stem material. The particle size reduction device may be a milling / cutting / shredding device. In one embodiment, the size reduction device is a hammer mill. A hammer mill has advantageously been found to reduce the amount of dust that is generated. In another embodiment, the particle size reduction device is a centrifugal cutter. In another embodiment, the particle size reduction device is a shredder. The shredder may, for example, shred short stem and stem fibres. In another embodiment, the tobacco material is pre-sized without any milling / cutting / shredding of the stem material and, instead, the stem material is sorted, with stems having a particle size outside a certain range being removed. This pre-sizing may involve sieving the stem material with a mesh that has, for example, a mesh size of 3 mm and rejecting stem material that does not pass through the sieve. If, for example, the Dpso and / or Dpgo value is still larger or smaller than a target value

[0228] (for example, 3 mm) then the material can be passed through further sieves to remove material that is too large / small as appropriate until the target Dpso and / or Dpgo value is achieved, or material of a certain size can be added to achieve a target Dpso and / or Dpgo value. In some embodiments, the tobacco material is pre-sized to have a particle size of less than 2 mm (e.g. mesh size No. to). In some embodiments, the stem material is presized to have a particle size of less than 1.9 mm, 1.8 mm, 1.7 mm, 1.6 mm, or 1.5 mm. The pre-sizing maybe optical (e.g. using a microscope), using sieves, or using a sorting or sieving machine. In one embodiment, the stem material is pre-sized to have a particle size of less than 1.68 mm (e.g. mesh size No. 12).

[0229] Step S2 - combining the materials to form the initial material

[0230] In some embodiments, the step (S2) of forming the initial material further comprises combining the pre-sized clove stem material and pre-sized tobacco material with further materials, such as additional fines material, and / or tobacco winnowings.

[0231] Two mixing steps may be performed to ensure adequate mixing of the pre-sized clove and tobacco particulate materials. The use of two mixing steps has been found to improve the homogeneity of the mixture of the pre-sized clove and tobacco particulate materials, which improves the bonding of the particles during the production of the non-continuous clove blend material, and as a result, improves the quality of the material. Moreover, further improvements have been found to be achieved by the use of a slower mixing speed and a longer duration. In comparison to previous methods, such as those used to produce material substantially comprising only tobacco, the mixing duration may be at least 120% or 150% longer, such as, for example no or 120 minutes versus 90 minutes previously. Likewise, the use of a slower mixing speed has been found to be advantageous in improving the homogeneity of the mixture of particles, and the mixing speed may be less than 80% or less than 70% of the speed used in the manufacture of previous materials, such as, for example, less than 8.0, preferably less than 6.0 rpm.

[0232] In addition to improving the homogeneity of the mixture, the use of slower mixing and screw extrusion speeds have been found to be particularly advantageous with the use of clove stem material to prevent the material from clumping, sticking to the machinery, and from damage resulting in the reduction of aroma and other sensory properties.

[0233] Step Si - processing the initial material At step (S3), the initial material is subjected to increased mechanical pressure and in particular also increased temperature and moisture. The initial material is brought to a pre-defined increased moisture content.

[0234] The material to be processed is also subjected to an increase in temperature, which may be obtained in particular by applying heat from outside and / or by mechanically generating pressure.

[0235] In some embodiments, the initial material is heated to a temperature of 6o°C to 180 °C, preferably too °C to 140 °C, and preferably no °C to 130 °C.

[0236] In some embodiments, the initial material is brought to a pressure of 10 to 200 bar, in particular 40 to 150 bar, preferably 60 to 120 bar. Pressures referred to herein refer to above atmospheric pressure, unless otherwise stated. In some embodiments, the dwell time of the initial material may be less than 3 minutes, in particular less than 2 minutes and preferably less than 1 minute.

[0237] As a result of step (S3), the clove stem material and tobacco material, includes the fines materials, are bound together to produce a non-continuous clove blend material that may be used subsequently for the production of aerosol provision systems. This obviates the need for expensive separate processes.

[0238] As a result of this process, there is a significant shift in size distribution towards larger particles.

[0239] The initial material is therefore subjected to a mechanical pressure at an increased temperature and defined moisture level (e.g. in an extruder or a conveyor screwconditioner). Due to the mechanical pressure, the clove stem material is pressed and bound together with the tobacco material. As a result of this, the binding of the materials is so strong that the resulting the non-continuous clove blend material is resistant to the normal stresses which occur during smoking article production. For example, fine material is not lost from the material as it is being conveyed by air under normal production conditions. Mechanical stability is therefore higher than is the case with conventional tobacco film materials. A higher proportion of clove stem material in the initial material is advantageous because it means that more of the clove stem material, which is otherwise a waste byproduct of clove bud production, that would otherwise be disposed of, can instead be commercially utilized. In addition, the level of eugenol in the clove stem material is much higher than the level in clove bud material, and this is compensated by the use of a higher proportion of clove stem material in the initial material.

[0240] Generally, the ratio of clove stem material and other material in the initial material may be from 35:65 to 70:30, such as 40:60, 50:50 or 60:40 (clove stem : other material). For example, the ratio of clove stem material and tobacco material in the initial material may be from 35:65 to 70:30, such as 40:60, 50:50 or 60:40 (clove stem : tobacco).

[0241] As a result of step (S3), it is not necessary to add extra or external binding agents to bind the clove stem material and the tobacco stem, neither binding agents that are foreign to the clove or tobacco nor inherent binding agents, i.e. which naturally occur in the clove or tobacco.

[0242] Instead, the clove stem material and the tobacco material can be bound mechanically and / or by the quantities of binding agents which naturally occur in the clove and / or tobacco (inherent binding agents). Such inherent binding agents (for example, starch, resins, and sugars) are activated and thus bind the clove stem material and the tobacco material. This is in contrast to methods that rely on the addition of binding agents, including methods of producing films or agglomerates that rely on the addition of binding agents. The capacity of the constituents of the initial material to bind together has also been found to be significantly influenced by the particle size and size distribution of the pre-seized clove stem material and pre-seized tobacco material.

[0243] The processing preferably results in a product which is a non-continuous clove blend material, in particular a fibrous and / or granular material or filler material. In other words, the method results in a product which is ready for consumption and can be used directly in an aerosol provision system, for example, to produce a rod of material for a cigarette or a tobacco heating device. This is veiy different from producing a material film (continuous material), which is more complex to produce and which still has to be cut and dried after production. The product obtained as a result of the present disclosure is of a size and moisture content which make it suitable for use directly as a filler material for aerosol provision systems, including cigarettes and tobacco heating devices.

[0244] In some embodiments, the initial material is processed in batches, in particular pressed in batches, for example, in a piston-cylinder unit.

[0245] Step S4

[0246] At step (S4), the feeding of the initial material through the shearing gap to form a non- continuous clove blend material promotes defibration of the material.

[0247] In some embodiments, on leaving the shearing gap and entering the atmosphere, the entrained water evaporates abruptly and optionally also other entrained ingredients, which, in addition to the shearing effect, causes the material to be defibrated and expanded in the shearing gap. The moisture of the material is reduced due to the flash evaporation, depending on the process pressure and temperature.

[0248] It has been found to be advantageous if the shearing gap surfaces are moved relative to one another to prevent and clear blockages. This ensures that the full cross-sectional surface of the gap is used and constant physical conditions prevail at the gap, which ultimately results in a uniform product. To this end, it has also proved to be of advantage if the gap surfaces are structured or profiled, for example, having grooves, as will be described in more detail below.

[0249] Step SF; At step (S5), the non-continuous clove blend material is cooled, for example from above too°C to room temperature, which may take place on a conveyor belt on the basis of air suction and may be operated from underneath.

[0250] During the cooling process the non-continuous clove blend material loses more moisture due to cooling by evaporation. The cooled material may have a moisture content, for example, in the range of 16-20%, preferably 17-19%.

[0251] In some embodiments, the non-continuous clove blend material is fed through an expansion and drying process, after which the non-continuous clove blend material will have a reduced moisture content, for example, in the range of 16-20%, preferably 17- 19%. Examples

[0252] These properties of the non-continuous clove blend material produced by the method of Fig. 1 were observed by manufacturing and comparing samples of three types of cigarette.

[0253] All three types of cigarette had the same size and dimensions, and contained the same total quantity of material. The first type of cigarette was a control cigarette in which the material consisted entirely of a non-continuous tobacco material produced by a method corresponding to the disclosed method, but using only tobacco material.

[0254] The second type of cigarette was equivalent to the control cigarette in all respects except that the material was a blend comprising 87.5% by mass of the material used in the control cigarette and 12.5% by mass of a non-continuous clove blend material produced by the disclosed method.

[0255] The third type of cigarette was equivalent to the control cigarette in all respects except that the material was a blend comprising 75% by mass of the material used in the control cigarette and 25% by mass of the same non-continuous clove blend material used in the second type of cigarette.

[0256] Batches of the first, second, and third types of cigarette were then tested using a smoking machine under standardised conditions to measure various parameters of the smoke and cigarette properties. The averages of the results obtained for each type of cigarette are shown in the table below.

[0257] The results show that the non-continuous clove blend material produced by the disclosed method, relative to control cigarettes, containing only an equivalent non- continuous tobacco material, has an increased eugenol content, but there is no significant difference in the tar and nicotine deliveiy, or the puff number.

[0258] The Test cigarettes having 25% inclusion of non-continuous clove material (Test cigarettes 2) were found to generate a clove aroma and taste comparable to those of conventional Kretek cigarettes, which comprise clove bud material.

[0259] Apparatus embodiments

[0260] Referring now to FIG. 2, a processing apparatus 1 is shown. In the present embodiment, the processing apparatus 1 is a pressure defibration device 1. The pressure defibration device 1 comprises a chamber housing 2 with a conveyor screw 3 disposed therein, which is rotated by means of a drive mechanism 4, for example, an electric motor 4.

[0261] The pressure defibration device 1 further comprises an initial material inlet 5A, a water inlet 6A and a casing and / or flavouring inlet 6B. The pressure defibration device 1 may further comprises a steam inlet 7.

[0262] The initial material is supplied to the initial material inlet 5A to enter the chamber housing 2, wherein the initial material passes along the chamber housing 2 upon rotation of the conveyor screw 3 such that the initial material passes from the initial material inlet 5A to an outlet 5B. At the outlet 5B of the chamber housing 2 is a head 8, which comprises a generally conical recess 8A.

[0263] A shearing member 10 is received in the recess 8A. A shearing gap 9 is formed between the shearing member 10 and the inner wall of the recess 8A. The initial material is conveyed through the gap 9 by the screw 3. The outlet 5B of the chamber 2 is in the form of an orifice that communicates the interior of the chamber 2 with the recess 8A. The orifice may be disposed at the gap apex of the generally conical recess 8A. The discharged material is denoted by reference number 12. In some embodiments, the shearing member to is in the form of a cone. The shearing gap 9 may be annular. The shearing member to is coupled to an actuator mechanism n that is configured to rotate the shearing member to. The shearing member to can be rotated about its central axis, the rotation indicated by the bent arrow in FIG. 2. In some embodiments, the actuator mechanism 11 comprises an electric motor. In some embodiments, the actuator mechanism 11 is configured to move the shearing member 10 axially in order to adjust the size of the gap 9.

[0264] The axial movement of the shearing member 10 is indicated by the double arrow in

[0265] FIG. 2, showing that the shearing member 10 can be moved towards and away from the head 8. Therefore, the shearing member 10 can be securely retained in its axial position, but may also be moved axially. As a result of this, the width of the gap 9 can be adjusted or adapted and, in some embodiments, a counter-pressure can be generated in the direction of the closure of the gap 9. The actuator mechanism 11 may be configured to move the shearing member 10 axially using a hydraulic or pneumatic actuator or using a linear gear arrangement such as a rack and pinion gear arrangement that is driven by an electric motor.

[0266] The first part of the processing of the initial material, at step (S3), takes place at a pressure above atmospheric pressure. This over pressure is generated as the initial material is conveyed along the chamber 2 via the screw 3 once it has been supplied to the inlet 5A.

[0267] The shearing gap 9 is disposed at the outlet end 5B of the chamber 2. The gap 9 virtually closes off the chamber 2 in the same manner as an extruder.

[0268] The gap 9 may be generally annular in cross-section. The width of the gap 9 in the axial direction of the conveyor screwed is determined by the axial position of the shearing member 10. Therefore, in embodiments wherein the axial position of the shearing member 10 is adjustable, the width of the gap 9 is also adjustable. In step (S3), the initial material is subjected to increased pressure (of up to 200 bar) and increased temperature (in particular above too°C). In addition to the mechanical pressure which occurs due to the initial material being conveyed towards the gap 9, additional forces also act on the initial material because shearing forces act in the pitches of the conveyor screw in conjunction with the walls which cause the initial material to be cut and defibrated. The shearing effect can be assisted by introducing draughts through the housing wall or by introducing additional flow resistances. In addition, steam may be introduced at several points in order to regulate the moisture, the temperature and the pressure in the conveyor screw or in the chamber 2. As a result of introducing steam and due to the natural moisture of the material, additional defibration of the initial material takes place on leaving the gap 9 because the water evaporates abruptly. Being under pressure, the moisture in the initial material evaporates abruptly as the pressure drops to atmospheric pressure downstream of the gap 9 and thus flash evaporation occurs.

[0269] In some embodiments, the initial material is placed under pressure mechanically, in particular mechanically pressed against the shearing gap 9 in the chamber 2. This being the case, the material may be placed under pressure by means of a conveyor screw, which presses the material towards the outlet end of the chamber 2 of a heatable screw conveyor, at which the shearing gap 9 is disposed. The initial material may also be coarsely pre-cut or coarsely pre-defibrated in the chamber 2 as it is fed towards the shearing gap.

[0270] In some embodiments, the shearing gap 9 is closed under pre-tensioning and is intermittently opened by the pressure of the initial material so that the material passes through the gap 9. Alternatively, the material may also advantageously be fed through a continuously opened shearing gap 9.

[0271] In some embodiments, the shearing gap 9 has a width in the range of 50 to 300 micrometres.

[0272] In some embodiments, the pressure chamber 2 has a conveyor system in the form of a plug screw feeder for conveying the initial material from the inlet 5A to the outlet 5B. In some embodiments pressure is generated by mechanical means, such as generated by a plug screw feeder for example, although other systems may also be used in principle within the context of the present disclosure, for example, using a piston system or alternatively, not mechanically or not only mechanically by using a gas pressure such as a pressurised gas supply.

[0273] If a plug screw feeder is used, in some embodiments it has reducing features which reduce the chamber volume in the region towards the outlet, for example, smaller screw pitches.

[0274] In some embodiments, mechanical pre-cutting features or pre-defibrating features are disposed in the pressure chamber 2. In one embodiment, a screw chamber pressure- conditioning device is disposed upstream of the device proposed by the invention in the same pressure chamber housing or in another one connected upstream. A pressure conditioning device of this type is described in patent DE 103 04 629 Al, for example, and can be combined with the pressure defibration device 1 of the present disclosure.

[0275] The pressure conditioning device 1 may incorporate all the structural features illustrated in FIG. 1 and explained in the associated description of DE 10304 629 Al and reference may be made to these construction features for further details.

[0276] In some embodiments, the pressure chamber 2 comprises inlets for conditioning agents or casing agents and flavourings.

[0277] The conditioning and pressure defibration processes depends on the pressure conditions under which conditioning takes place. In some embodiments, the initial material is conditioned under atmospheric conditions and is fed by means of a feeding apparatus, for example, conveyor chutes or a conveyor belt, into the inlet 5A, for example, via a hopper. One or more of the constituents of the initial material may be conditioned separately.

[0278] In some embodiments, the feeding apparatus comprises a silo (not shown) and a screw feeder (not shown). The initial material is stored in the silo and supplies the screw feeder, wherein the screw feeder supplies the initial material to the inlet 5A of the pressure defibration device 1.

[0279] The feeding apparatus may be configured to supply a predetermined flowrate of initial material to the processing apparatus 1. In some embodiments, the feeding apparatus is configured to supply initial material to the processing apparatus 1 at a flow rate in the range of 50 to 250 kg / h and, preferably, in the range of 95 to 175 kg / hour. The conditioning process may take place at an axially intermediate point of the chamber 2 by introducing water and casing at the respective inlets 6 A, 6B. In some alternative embodiments (not shown), the water and casing (and / or flavouring) are introduced at the same inlet, or only one of water and casing are introduced into the chamber 2.

[0280] At step (S4), the initial material passes through the gap 9 and is subjected to shearing between the walls of the head 8 and the shearing member 10 and also the flash evaporation mentioned above takes place on the material leaving the gap 9. Thus, the gap 9 acts as a shearing gap 9. The shearing and the flash evaporation both contribute to a well defibrated non-continuous clove blend product that can be used in aerosol provision systems. In some embodiments, the shearing member 10 is rotated about its rotational axis in order to help prevent blockages from occurring in the gap 9. This rotation of the shearing member 10 may be continuous or intermittent or the direction of rotation may be alternated. This being the case, the rotation may be a full rotation or only a quarter or one third rotation or rotations of smaller / larger units. In an alternative embodiment (not shown), the shearing member 10 is stationary and the head 8 is rotated, for instance, being coupled to a drive mechanism. However, it should be recognised that in yet further embodiments, the head 8 and shearing member 10 do not rotate relative to each other. In some embodiments, the head 8 and shearing member 10 comprise respective shearing surfaces 13, 14, wherein the gap 9 is formed between the shearing surfaces 13, 14. In some embodiments, the shearing surfaces 13, 14 are generally opposing.

[0281] In some embodiments, one or both of the shearing surfaces 13, 14 has one or more surface formations, for example, grooves or other roughening such as protrusions or depressions. In some embodiments, the surface formations, for example, grooves, may have a depth in the radial direction of at least 0.2 or at least 1 mm. The surface formations promote shearing of the initial material and may also promote more homogenous pressure conditions which leads to a more homogenous end product. In some embodiments, the grooves extend parallel to the central axis of the shearing member 10. In some embodiments, the shearing member to comprises more than 80 grooves and, preferably, at least 90, too, 120, 140, 160 or 180 grooves. In some embodiments, the grooves each have a maximum width in the range of 0.5 to 1.5 mm. The width of each groove may be constant or may vary. It has been found that a smaller groove width results in smaller lighter fibres in the defibrated non-continuous clove blend material. The width of the grooves is in the circumferential direction of the shearing member 10.

[0282] In some embodiments, the shearing surfaces 13, 14 are moveable apart from one another and towards one another. In some embodiments, the shearing member 10 is biased relative to the head 8 such that the shearing surfaces 13, 14 abut and thus the gap 9 is closed. Alternatively, the shearing surfaces 13, 14 are moveable apart from one another and towards one another with a fixed or fixedly adjustable distance, in which case the shearing surfaces 13, 14 lie at a fixed distance of 10 to 2000 microns, and preferably 50 to 300 microns. These figures relate to smooth shearing surfaces 13, 14. Alternatively, if the shearing surfaces 13, 14 comprise, for example, grooves then the distance refers to the distance between the parts of the surfaces 13, 14 between the grooves.

[0283] In some embodiments, the grooves of the shearing member 10 extend longitudinally or transversely to the direction in which the shearing surfaces 13, 14 move. In some embodiments, the shearing surface 14 of the head 8 is stationary whereas the shearing surface 13 of the shearing member 10 is displaced axially. In some embodiments, the shearing surface 14 of the head 8 is displaced axially whereas the shearing surface 13 of the shearing member 10 is held stationary. In some embodiments, the shearing surface 14 of the head 8 is stationary whereas the shearing surface 13 of the shearing member 10 is rotated. In some embodiments, the shearing surface 14 of the head 8 is rotated whereas the shearing surface 13 of the shearing member 10 is held stationary.

[0284] Rotation and axial movement of the shearing surface(s) 13, 14 may be caused by the same actuator mechanism 1. Alternatively, a first actuator mechanism may rotate one of the shearing surfaces 13, 14 whereas a second actuator mechanism may axially displace said one or the other one of the shearing surfaces 13, 14.

[0285] In some embodiments, the shearing surfaces 13, 14 are moved towards one another continuously or intermittently or in one or two directions or backwards and forwards.

[0286] In some embodiments, the gap 9 may be an annular gap, preferably a conical gap.

[0287] At step (S5), the material is cooled. The material may be cooled whilst being transported, for example, on a conveyor belt.

[0288] The resultant, defibrated process product exhibits similar properties to those of stems processed by shredders in terms of appearance and use. However, the pressure defibration processes and device of FIG. 2-4 do not have the disadvantage of causing a lot of dust, as is the case when stems are processed by shredders, and moistening is not necessary to such a high degree, which enables subsequent drying to be significantly reduced or dispensed with.

[0289] The produced non-continuous clove blend material may be a re-constituted material that is binder free.

[0290] Referring now to FIG. 3, another an embodiment of a processing apparatus is shown.

[0291] The processing apparatus comprises a pressure defibration device 1 of the type described above with reference to FIG. 3. The processing apparatus further comprises a pressure conditioning device 20 connected upstream of the pressure defibration device

[0292] 1.

[0293] The pressure defibration device 1 and pressure conditioning device 20 form part of a combined pressure conditioning and defibration system.

[0294] The pressure conditioning device 20 may be of the type illustrated in particular in FIG.

[0295] 1 of patent specification DE 103 04 629 At and described in the associated part of the description. The latter is included herein by way of reference. It has a initial material inlet 25 and a differential pressure-proof cellular wheel sluice 26 through which the initial material is introduced into the pressure chamber 21, where it is transported with the aid of a conveyor screw 22. The conveyor screw 22 is driven by a drive mechanism, for example, a motor 24.

[0296] Disposed at the end of the chamber 21 is an outlet 27 for the initial material, which feeds the inlet 5A of the pressure defibration device 1. In some embodiments, unlike the device described in patent specification DE 103 04 629 At there is no differential pressure-proof sluice at the outlet of the pressure conditioning device. Instead, the initial material is transferred to the inlet 5A of the pressure defibration device 1 by the pressure of the chamber 22.

[0297] In other embodiments, the outlet from the pressure conditioning chamber 22 is operated using a cellular wheel sluice and decreasing the pressure. In such embodiments, the initial material may be transferred to the pressure defibration process at a lower pressure than in the pressure conditioning chamber, for example, ambient pressure. In some embodiments, the initial material is first treated by the pressure conditioning device 20 and is then transported to a separate pressure defibration device 1. The initial material may be manually transported between the pressure conditioning device 20 and pressure defibration device 1 or automatically, for example, using a conveyor belt or pneumatic conveyor.

[0298] However, it is preferable to avoid a drop in pressure during the transfer from the pressure conditioning device 20 to the pressure defibration device 1 to enable an above atmospheric pressure to be applied across the entire processing region from the start of conditioning through to the defibration process, as illustrated. The initial material is fed through the differential pressure-proof cellular wheel sluice 26. The pressureproofing of the sluice 26 at one end and the gap 9 which is always filled with defibrated material during operation make it possible to maintain a pressure above atmospheric pressure throughout the combined device. To this end, sealing of the cellular wheel sluice 26 may be optimised by heating its housing.

[0299] Once the initial material has been introduced into the chamber 22, the material is at a pressure above atmospheric pressure, which may be maintained by introducing steam to compensate for the natural leakage rates of the cellular wheel sluice 26 (gaps and spillage volumes). The initial material is heated by the steam and the moisture content increased. In principle, it would also be possible to operate a drying process in such a chamber using over-saturated steam, but when used for defibration, it is usually of advantage if the initial material introduced has a higher moisture content.

[0300] The initial material is conveyed through the conditioning chamber 21 by the conveyor screw 22. Different settings may be used for this purpose (pitch of the screw, rotation speed and inclination of the chamber), by means of which the dwell time of the initial material can be set. In some embodiments the dwell time is between 2 and 10 minutes.

[0301] After the pressure conditioning process, during which water, casing and / or flavouring material may also be added, the initial material is then transferred through the outlet

[0302] 27 into the pressure defibration device 1. The process of introducing the initial material may also be made easier if the housing is also of a hopper-type design. In some embodiments, the typical dwell time of the initial material in the pressure defibration device 1 is less than 2 minutes, in particular less than 1 minute. The material may then leave the pressure defibration device 1 in the desired state described above.

[0303] Instead of the pressure conditioning screw, it would also be possible to use a conditioning screw operating at below atmospheric pressures. In some embodiments, the pressure defibration device 1 comprises a single or twin screw conveyor with a shearing gap outlet for defibrating material. The shearing gap comprises an orifice, through which the material is sheared as it passes through.

[0304] FIG. 4 illustrates another embodiment of a combined pressure conditioning and defibration system. The pressure conditioning device 20 and the pressure defibration device 1 are similar to those described above in reference to FIGS. 2 and 3, and therefore a detailed description will not be repeated hereinafter. A difference is that the conveyor screw of the conditioning device 20 and the defibration screw of the pressure defibration device 1 are provided on the same shaft and are driven by a single motor. If the same rotation speed is used for both screws, the different dwell times in the two process steps may be obtained using different methods, for example, by different crosssections / volumes or release options in the region of the conditioning process.

[0305] In the embodiments of FIGS. 3 and 4, the steam and conditioning agents, for example, water and casing, are introduced through the appropriate inlets of the pressure conditioning device 20. Corresponding water, conditioning and steam inlets are omitted from the pressure defibration device 1. Flavouring and / or casing can be introduced in both pressure ranges, i.e. in one or both of the pressure chambers, or at atmospheric pressure, i.e. outside of the chambers. Density

[0306] In some embodiments, the produced non-continuous clove blend material has a bulk density in the range of 230 to 600 kg / ms, such as 240 to 340 kg / ms, or 250-300 kg / m'1. This density is much lower than the density of tobacco-only non-continuous materials, which is believed to result from the properties of the clove stem material and the relative sizes of the clove stem and other (e.g. tobacco stem) particles used in the production of the present material. This finding is highly advantageous because the lower density of the material means that a lower quantity of starting material by mass is required to produce an equivalent volume of non-continuous material. The bulk density may be calculated as mass / volume for a specific material.

[0307] Delivery Systems

[0308] The present disclosure also relates to manufacturing a component for a deliveiy system such as an aerosol provision system.

[0309] The delivery system described herein can be implemented as a combustible aerosol provision system, a non-combustible aerosol provision system or an aerosol-free delivery system. The non-continuous clove blend material may be a smokable material.

[0310] The method may comprise combining the non-continuous clove blend material with a tobacco material, for example, cut tobacco, to form a mixture; and then forming the component from the mixture.

[0311] The non-continuous clove blend material may be combined with a Kretek material.

[0312] In some embodiments, the mixture comprises at least 5% non-continuous clove blend material and, preferably, at least 7%, 10%, 12%, 15%, 18%, 20% or 25% non-continuous clove blend material, by mass, for a combustible product. In some embodiments, the mixture comprises about 12.5% or about 25% non- continuous clove blend material, by mass, for a combustible product.

[0313] In some embodiments, the tobacco mixture comprises 25% or less non-continuous clove blend material, by mass, for a combustible product such as a combustible aerosol provision system.

[0314] In some embodiments, for a non-combustible product, for example, a non-combustible aerosol provision system, the tobacco mixture comprises, preferably, at least 5%, and up to 100% non-continuous clove blend material, by mass.

[0315] In some embodiments, there is provided a component for a non-combustible aerosol provision system, the component comprising expanded tobacco material, such as DIET. The method as described herein results in non-continuous clove blend material which is expanded, and expanded material can be provided in, for instance, an aerosol generating portion of an article for use in the non-combustible aerosol provision system, or the non-combustible delivery system, as described herein. There is also provided a non-combustible delivery system or a non-combustible aerosol delivery system comprising expanded material, for instance the non-continuous clove blend material produced by the methods described herein. The non-combustible aerosol provision system can, for instance, be a tobacco heating product, or a hybrid system to generate aerosol using a combination of aerosol-generating materials, where one of the materials is an non-continuous clove blend material. An expanded material can also be used in an aerosol-free delivery system that delivers at least one substance to a user orally, nasally, transdermally or in another way without forming an aerosol, including but not limited to, lozenges, gums, patches, articles comprising inhalable powders, and oral products such as oral tobacco which includes snus or moist snuff, wherein the at least one substance may or may not comprise nicotine. The expanded material may be produced by exposing a material to a drop in pressure resulting in flash evaporation. Alternatively or in addition, the expanded material may be produced by feeding material through a shearing gap such that the material is defibrated by expansion.

[0316] In some embodiments, the component is for a combustible aerosol provision system or for a non-combustible aerosol provision system. In some embodiments, the component is a rod of material. The present disclosure further relates to an aerosol provision system and to parts of the aerosol provision system comprising non-continuous clove blend material manufactured according to the present disclosure. As used herein, the term “delivery system” is intended to encompass systems that deliver at least one substance to a user, and includes: combustible aerosol provision systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for roll-your-own or for make-your-own cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokable material) ; non-combustible aerosol provision systems that release compounds from an aerosol-generating material without combusting the aerosol-generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol-generating materials; and aerosol-free delivery systems that deliver the at least one substance to a user orally, nasally, transdermally or in another way without forming an aerosol, including but not limited to, lozenges, gums, patches, articles comprising inhalable powders, and oral products such as oral tobacco which includes snus or moist snuff, wherein the at least one substance may or may not comprise nicotine.

[0317] As used herein, the term “aerosol provision system” is intended to encompass combustible and non-combustible aerosol provision systems that deliver at least one substance to a user, and includes: combustible aerosol provision systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for roll-your-own or for make-your-own cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokable material); non-combustible aerosol provision systems that release compounds from an aerosol-generating material without combusting the aerosol-generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol-generating materials.

[0318] According to the present disclosure, a “combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is combusted or burned during use in order to facilitate delivery of at least one substance to a user. In some embodiments, the delivery system is a combustible aerosol provision system, such as a system selected from the group consisting of a cigarette, a cigarillo and a cigar.

[0319] In some embodiments, the disclosure relates to a component for use in a combustible aerosol provision system, such as a filter, a filter rod, a filter segment, a tobacco rod, a spill, an aerosol-modifying agent release component such as a capsule, a thread, or a bead, or a paper such as a plug wrap, a tipping paper or a cigarette paper.

[0320] According to the present disclosure, a “non-combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.

[0321] In some embodiments, the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system.

[0322] In some embodiments, the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0323] In some embodiments, the non-combustible aerosol provision system is an aerosol- generating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system.

[0324] In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine.

[0325] In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product. Typically, the non-combustible aerosol provision system may comprise a noncombustible aerosol provision device and a consumable for use with the noncombustible aerosol provision device. In some embodiments, the disclosure relates to consumables comprising aerosolgenerating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure. In some embodiments, the non-combustible aerosol provision system, such as a non- combustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source.

[0326] In some embodiments, the non-combustible aerosol provision system may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and / or an aerosol-modifying agent.

[0327] In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol-modifying agent.

[0328] In some embodiments, the substance to be delivered may be an aerosol-generating material or a material that is not intended to be aerosolised. As appropriate, either material may comprise one or more active constituents, one or more flavours, one or more aerosol-former materials, and / or one or more other functional materials.

[0329] Other Substances

[0330] The non-continuous clove blend material may comprise an aerosol forming material, which may also be referred to as a humectant. The aerosol forming material may comprise one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0331] Preferably, the non-continuous clove blend material may comprise glycerol and / or propylene glycol. The non-continuous clove blend material may comprise an aerosol forming material in an amount of 1-30%, 3-28%, by mass. Preferably, the non-continuous clove blend material may comprise an aerosol forming material in an amount of 5-25%, by mass. Preferably, the non-continuous clove blend material may comprise an aerosol forming material in an amount of 5-20%, by mass, such as in an amount of at least or about 15%, by mass.

[0332] In some embodiments, the substance to be delivered comprises an active substance.

[0333] The active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropics, psychoactives. The active substance may be naturally occurring or synthetically obtained. The active substance may comprise for example nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical.

[0334] In some embodiments, the active substance comprises nicotine. Nicotine may be applied to the non-continuous aerosol-generating material using any suitable method. For example, in some embodiments, nicotine may be applied to the non-continuous clove blend material by means of a suitable applicator, such as a spray. In addition or alternatively, in some embodiments, nicotine may be combined with the aerosol generating agent such as glycerol for inclusion in the non-continuous clove blend material. Nicotine may be included in the material in a final amount of about 0.1% to about 5% by weight of the aerosol-generating material. For example, the total amount of nicotine in the material may be from about 0.2% to about 4%, from about 0.5% to about 3%, such as about 1% or about 2% by weight of the non-continuous clove blend material.

[0335] The Nicotine content may be determined by any suitable method, such as, for example, using gas chromatography, or any other method that is used in the art to quantify the level of secondary alkaloids in tobacco. In some embodiments, including some embodiments in which the active substance comprises nicotine, the non-continuous clove blend material may comprise an acid. As a result, the aerosol-generating materials comprising acid may produce an aerosol with an appropriate composition such as nicotine content. The inclusion of an acid has been found to improve the release of other substances, such as nicotine, from the material. In some embodiments, the non-continuous clove blend material comprises the acid in an amount (i.e. moles of acid) from about 50% to about 200%, from about 75% to about 150%, from about 85% to about 140%, from about 95% to about 135%, from about 105% to about 130%, or from about 110% to about 125% relative to the moles of nicotine in the material. In some embodiments, the non-continuous clove blend material comprises the acid in an amount (i.e. moles of acid) from about 100% to about 200%, from about 100% to about 180%, from about 110% to about 180%, from about 120% to about 180%, from about 130% to about 180%, or from about 135% to about 180% relative to the moles of nicotine in the material.

[0336] The acid may be applied to the non-continuous clove blend material using any suitable method. The acid may be applied to the material together with another substance, such as nicotine and / or an aerosol forming material, or maybe applied separately. For example, in some embodiments, the ratio of the acid and aerosol forming material in the non-continuous clove blend material is from about 1:2 to about 1:50 (acid: aerosol forming material).

[0337] The acid may be applied to the non-continuous clove blend material using any suitable method. In some embodiments, the acid may be applied to the non-continuous aerosol- generating material after it has been produced. In some embodiments, the acid is selected from the group consisting of lactic acid, levulinic acid, benzoic acid, citric acid, 2-methylbutyric acid, or 2-methylvaleric acid. In some embodiments, the acid is lactic acid. In some embodiments, the acid is levulinic acid. The term lactic acid is synonymous with the term 2-hydroxypropanoic acid and covers both D and L enantiomers separately or a mixture thereof. For example, the lactic acid can be a mixture (for example a racemic mixture) of D-2-hydroxypropanoic acid and L-2-hydroxypropanoic acid. The term levulinic acid is synonymous with the term 4 -oxopentanoic acid. In some embodiments, the active substance is a legally permissible recreational drug.

[0338] In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12. The active substance may be CBD or a derivative thereof.

[0339] As noted herein, the active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof. As used herein, the term "botanical" includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like. Alternatively, the material may comprise an active compound naturally existing in a botanical, obtained synthetically. The material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like. Example botanicals include tobacco, clove, and any of the botanical materials listed above.

[0340] In some embodiments, the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is tobacco material.

[0341] In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is clove. Cloves contain several essential oils, for example eugenol, which is known to provide some of the characteristic taste of the clove and is considered to have an analgesic effect in traditional Chinese medicine. In some embodiments, the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from eucalyptus, star anise, cocoa and hemp. In some embodiments, the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from rooibos and fennel.

[0342] In some embodiments, the substance to be delivered comprises a flavour.

[0343] As used herein, the terms "flavour" and "flavourant" refer to materials which, where local regulations permit, may be used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavour materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice

[0344] (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, wintergreen, cheriy, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberiy, citrus fruits,

[0345] Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang- ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, maijoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavour enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas.

[0346] In some embodiments, the flavour comprises menthol, spearmint and / or peppermint. In some embodiments, the flavour comprises flavour components of cucumber, blueberry, citrus fruits and / or redberry. In some embodiments, the flavour comprises eugenol. In some embodiments, the flavour comprises flavour components extracted from tobacco. In some embodiments, the flavour comprises flavour components extracted from cannabis.

[0347] In some embodiments, the flavour may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucolyptol, WS-3.

[0348] Aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol-generating material may, for example, be in the form of a solid, liquid or gel which may or may not contain an active substance and / or flavourants. In some embodiments, the aerosolgenerating material may comprise an “amorphous solid”, which may alternatively be referred to as a “monolithic solid” (i.e. non-fibrous). In some embodiments, the amorphous solid may be a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the aerosolgenerating material may for example comprise from about 50wt%, 6owt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or ioowt% of amorphous solid. The one or more other functional materials may comprise one or more of pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and / or antioxidants.

[0349] The material may be present on or in a support, to form a substrate. The support may, for example, be or comprise paper, card, paperboard, cardboard, reconstituted material, a plastics material, a ceramic material, a composite material, glass, a metal, or a metal alloy. In some embodiments, the support comprises a susceptor. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is on one or either side of the material. A consumable is an article comprising or consisting of aerosol-generating material, part or all of which is intended to be consumed during use by a user. A consumable may comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and / or an aerosol-modifying agent. A consumable may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosol-generating material to generate aerosol in use. The heater may, for example, comprise combustible material, a material heatable by electrical conduction, or a susceptor. A susceptor is a material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically-conductive material, so that penetration thereof with a vaiying magnetic field causes induction heating of the heating material. The heating material may be magnetic material, so that penetration thereof with a vaiying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both electrically-conductive and magnetic, so that the susceptor is heatable by both heating mechanisms. The device that is configured to generate the varying magnetic field is referred to as a magnetic field generator, herein. An aerosol-modifying agent is a substance, typically located downstream of the aerosol generation area, that is configured to modify the aerosol generated, for example by changing the taste, flavour, acidity or another characteristic of the aerosol. The aerosolmodifying agent may be provided in an aerosol-modifying agent release component, that is operable to selectively release the aerosol-modifying agent.

[0350] The aerosol-modifying agent may, for example, be an additive or a sorbent. The aerosol-modifying agent may, for example, comprise one or more of a flavourant, a colourant, water, and a carbon adsorbent. The aerosol-modifying agent may, for example, be a solid, a liquid, or a gel. The aerosol-modifying agent may be in powder, thread or granule form. The aerosol-modifying agent may be free from filtration material. An aerosol generator is an apparatus configured to cause aerosol to be generated from the aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to heat energy, so as to release one or more volatiles from the aerosol-generating material to form an aerosol.

[0351] In some embodiments, the aerosol generator is configured to cause an aerosol to be generated from the aerosol-generating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy.

[0352] In order to address various issues and advance the art, the entirety of this disclosure shows by way of illustration various embodiments in which the claimed invention(s) may be practiced and provide for superior manufacture of tobacco material. The advantages and features of the disclosure are of a representative sample of embodiments only, and are not exhaustive and / or exclusive.

[0353] The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and / or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc, other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future.

Claims

Claims1. A method of manufacturing non-continuous clove blend material, the method comprising: providing pre-sized particulate clove stem material having a Dpgo particle size of less than 2mm; producing an initial material, wherein the initial material comprises at least 5%, by mass, of the clove stem material; and, processing the initial material by subjecting the initial material to an increased mechanical pressure to thereby produce the non-continuous clove blend material.

2. A method according to claim 1, wherein the initial material comprises at least 35%, by mass, of the clove stem material.

3. A method according to claim 1 or claim 2, wherein the initial material comprises between 50% and 70%, by mass, of the clove stem material.

4. A method according to any one of claims 1-3, wherein providing pre-sized particulate clove stem material comprises: separating clove stem material from other parts of the clove plant, including removing clove bud material; reducing the size of the clove stem material; and selecting particulate clove stem material having a particle size of less than 2mm.

5. A method according to any one of claims 1-4, wherein the pre-sized particulate clove stem material comprises:(a) at least 50%, by mass, of material having a particle size less than 0.5mm; and / or(b) 10-25%, by mass, of material having a particle size greater than 0.5mm and smaller than 2mm.

6. A method according to any one of claims 1-5, wherein processing the initial material comprises the use of a water flow rate of 14-16 L / h.

7. A method according to any one of claims 1-6, wherein the method comprises processing the initial material by: setting the initial material to a predefined increased moisture content;subjecting the initial material to an increase in temperature; and subjecting the initial material an increased pressure.

8. A method according to any one of claims 1-7, wherein processing the initial material comprises pressurising the initial material to a pressure in the range of 40-50 bar.

9. A method according to any one of claims 1-8, wherein the method further comprises feeding the processed material through a shearing gap, wherein the shearing gap is arranged between shearing surfaces, wherein a rotatable shearing member comprises one of the shearing surfaces, and wherein the method comprises rotating the shearing member at an angular velocity of 500-850 rpm.

10. A method according to any one of claims 1-9, wherein the method further comprises: providing pre-sized tobacco material having a Dpgo particle size of less 3 mm and a Dpso particle size of less than 2 mm; producing the initial material by combining the particulate clove stem material and the tobacco material; and, processing the initial material by subjecting the initial material to an increased mechanical pressure to bind the clove stem material and the tobacco material to thereby produce the non-continuous clove blend material.

11. A method according to claim 10, wherein the pre-sized tobacco material comprises:(a) tobacco stem material;(b) less than 40%, by mass, of material having a particle size less than 0.5mm; and / or(c) at least 60%, by mass, of material having a particle size greater than 0.5mm and smaller than 2mm.

12. A method according to claim 10 or claim 11, wherein the total amount of particulate clove stem material, tobacco material, and water in the initial material comprises at least 95% of the initial material, by mass.13- A method according to any one of claims 10-12, wherein the non-continuous clove blend material includes:(a) no other materials or additives in addition to substances naturally found in clove stem material and tobacco material; and / or (b) no clove bud material.

14. A method according to any one of claims 1-13, wherein the non-continuous clove blend material has a strand length wherein:(a) at least 75% of the strands have a strand length of at least 20mm; and / or (b) at least 20% of the strands have a strand length of at least 40mm.

15. A method according to any one of claims 1-14, wherein the non-continuous clove blend material has a bulk density of 230 to 600 kg / m3, preferably 240 to 340 kg / m3.

16. A method according to any one of claims 1-15, wherein the non-continuous clove blend material has a eugenol content of 0.8-2% on a dry weight basis.

17. A method according to any one of claims 1-16, wherein the non-continuous clove blend material has a moisture content of at least 16%.

18. A method according to any one of claims 1-17, wherein the non-continuous clove blend material has a water content of at least 15%, measured using a Karl Fischer titrator.

19. A method according to any one of claims 1-18, wherein the non-continuous clove blend material has a filling power of greater than 32 cm'1 / 10g.

20. A method according to any one of claims 1-19, wherein the non-continuous clove blend material comprises an aerosol forming material in an amount of 5-30%, preferably 15-20%, by mass.

21. A method according to claim 20, wherein the aerosol forming material comprises glycerol, propylene glycol, or a mixture of glycerol and propylene glycol.

22. A method according to any one of claims 1-22, wherein the non-continuous clove blend material comprises an active substance, preferably wherein the active substance is selected from nutraceuticals, nootropics and psychoactives.

23. A method according to claim 22, wherein the active substance comprises nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations, or one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical.

24. A method according to claim 23, wherein the active substance comprises nicotine or a nicotine salt.

25. A method according to claim 24, wherein the non-continuous clove blend material comprises nicotine in an amount of up to 3% by weight.

26. A method according to any one of claims 1-25, wherein the non-continuous clove blend material comprises an acid in an amount of 0.1-5% by weight of the non- continuous clove blend material.

27. A method according to claim 26, wherein the acid comprises lactic acid, benzoic acid, citric acid, levulinic acid, 2-methylbutyric acid, and / or 2-methylvaleric acid.

28. A method according to any one of claims 20-25, comprising applying the aerosol forming material, the active substance, and / or the acid: (a) to the initial material prior to or while subjecting the initial material to the increased mechanical pressure; and / or(b) to the non-continuous clove blend material after subjecting the initial material to the increased mechanical pressure.

29. A non-continuous clove blend material, wherein the material comprises at least35%, by mass, of clove stem material.

30. A non-continuous clove blend material according to claim 29, wherein the material further comprises tobacco material.

31. A non-continuous clove blend material according to claim 29 or claim 30, wherein the material further comprises an additive selected from:(a) an aerosol forming material; and / or(b) an active substance.

32. A non-continuous clove blend material produced, obtained, or obtainable by the method of any one of claims 1-28.

33. A component for a delivery system, wherein the component comprises non- continuous clove blend material according to any one of claims 29-32.

34. A component according to claim 33, wherein the component is for an aerosol provision system. 35- A component according to claim 34, wherein the component is combusted to generate an aerosol.

36. A product comprising a component according to any one of claims 33-35.

37. An article for use in or as an aerosol provision system, the article comprising a component according to any one of claims 33-35.

38. Use of a non-continuous clove blend material according to any one of claims 29- 32 in an aerosol provision system.

39. An article for use in an aerosol provision system comprising a non-continuous clove blend material according to any one of claims 29-32.

40. A system comprising a non-continuous clove blend material according to any one of claims 29-32, and a device arranged to heat the non-continuous aerosolgenerating material and generate an aerosol from the non-continuous aerosolgenerating material.

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