Work island and method for making rod-shaped segments for the smoking article industry

Abstract

Described is a work island (1) for making rod-shaped segments (S) for the smoking article industry in a continuous process. The work island comprises a machine (100) for making a multilayer web (N) formed from at least one layer of plant-based reconstituted material and at least one reinforcing layer. This machine (100) includes a feed unit (50) for feeding a continuous reinforcing layer (R) which is fibre-based and / or made at least partly of a conductive material, a feed unit (10) for feeding a moist, plant-based material (M), a forming unit (20) which combines (M) and (R), and a drying unit (30) for removing moisture from the plant-based layer. Downstream, a machine (200) converts the multilayer web (N) into rod-shaped segments (S), operating in sequence relative to the machine (100).

Description

[0001] This invention relates to a work island and to a method for making rod-shaped segments for the smoking article industry.

[0002] In the prior art of the sector relevant to this invention, rod-shaped segments are made for the purpose of manufacturing aerosol generating articles. The conventional production process comprises an initial ("primary") step, performed by a dedicated machine, where a web of reconstituted plant-based material is obtained. This material is made by processing composite mixtures, classifiable according to their moisture content, which are converted into web-like sheets, dried and, if necessary, cut into narrower sub-webs, and wound in rolls for storage.

[0003] This is followed by a ("secondary") step, performed by another machine, in which the web is unrolled, subjected to supplementary cutting (parallel or transverse) and then dynamically crimped to form a continuous strand. The latter is wrapped in porous material or functional sheets (e.g. of aluminium foil or cellulose) and cut transversely to obtain a succession of rod-shaped segments for the smoking article industry.

[0004] The Applicant has found that this process has inherent disadvantages, linked in particular to the limited tensile strength of the dried web. At high operating speeds, especially during the second step of the process, the dynamic stress causes the material to deform permanently or tear.

[0005] This incompatibility between the stress of the second step of the process (performed at a higher speed than the first step of the process) and the fragility of the web prevents inline integration of the two machines, which typically operate at different speeds (the "secondary" machine operates at a much higher speed than the "primary" machine), making the two machines incompatible with inline connection.

[0006] Moreover, the disadvantages are made even worse by the fact that the primary and secondary machines are typically located far apart, often in different rooms. Transferring the rolls manually from one department to the other is highly time-consuming and not only increases production costs but also creates the risk of deteriorating the material on the rolls.

[0007] In this context, the technical purpose of this invention is, therefore, to provide a work island and a method for making rod-shaped segments for the smoking article industry to overcome the disadvantages of the prior art. This invention therefore has for an aim to provide a work island and a method for making rod-shaped segments for the smoking article industry and capable making the process more efficient while maintaining the quality of production at a high level.

[0008] The technical purpose and aim specified are substantially achieved by a work island and a method for making rod-shaped segments for the smoking article industry according to claims 1 and 10 and / or one or more of the claims dependent thereon.

[0009] As will become clearer as this description continues, the expression "work island" is used to mean an integrated agglomerate of machine and operating unit which cooperate synergically in the context of the same production process, forming part of a single plant which is physically located in a defined area. In such a configuration, the machines are positioned close together, or even interconnected, so as to operate inline continuously, thereby ensuring an optimized, uninterrupted production flow. In any case, as made clearer as this description continues, even if the process is not entirely inline, the fact that the operating units are close to each other ensures reduced transfer times and a significantly accelerated production process, which translates as improved efficiency and lower operational costs.

[0010] The aforementioned work island performs a continuous process and comprises a machine for making a continuous, multilayer web of the smoking article industry and at least one machine for making rod-shaped segments for the smoking article industry, connected downstream of the machine which makes the multilayer web.

[0011] The machine for making a multilayer web is configured to make a multilayer web comprising at least one layer of plant-based reconstituted material and at least one reinforcing layer.

[0012] The machine for making a multilayer web comprises a feed unit for feeding a continuous reinforcing web and a feed unit for feeding a moist, plant-based material.

[0013] The expression "reinforcing web" is used to mean a web characterized by high mechanical properties, in particular a tensile strength which is significantly higher compared to the layer of material of plant origin. The reinforcing web, which may be made of a fibre-based material and / or at least partly of a conductive material (electrically conductive, preferably susceptible to heating by electromagnetic induction) may comprise substrates of paper, grid-like mesh or thin sheets of conductive metallic material, thus contributing to enhancing the stability and overall durability of the multilayer web.

[0014] In addition, the expression "moist material" is used to mean a plant-based amalgam, usually made from a dry product of plant origin (tobacco and / or substitutes thereof), mixed with water and active, aerosol-generating components. This amalgam may be further enriched with functional additives, such as humectants, emulsifiers and binders, designed to ensure a smooth consistency and the correct plasticity during forming operations. Depending on its degree of hydration, the moist material may come in different forms and consistencies, varying from a shapeless mixture to a preformed sheet.

[0015] The machine for making a multilayer web then comprises a forming unit, located downstream of the two feed units and configured to receive and combine the moist, plant-based material and the reinforcing web to make a continuous, at least partly multilayer web.

[0016] The term "combine" is used to mean the use of any process or technique, typically mechanical, which allows joining the moist material and the reinforcing web, so that the former is fixed permanently and uniformly to the latter and thus forms a continuous multilayer web. Depending on the nature of the reinforcing web, the moist material may adhere to the surface of it or may interpenetrate it partly or completely.

[0017] The machine for making a multilayer web then comprises a drying unit, located downstream of the forming unit and configured to remove a substantial quantity of moisture at least from the layer of material of plant origin.

[0018] The expression "remove a substantial quantity" is used to mean reducing the moisture content to a significant and controlled extent, such as to give the multilayer web a desired moisture content, as well as structural stability and suitable mechanical properties.

[0019] The at least one machine for making rod-shaped segments, located downstream of the machine for making a multilayer web, is configured to form the multilayer web into rod-shaped segments for the smoking article industry. This machine is of known type, based on state-of-the-art technology.

[0020] In particular, the machine for making rod-shaped segments for the smoking article industry operates in sequence relative to the machine for making a multilayer web of the smoking article industry. In other words, the machine for making rod-shaped segments receives the web continuously and converts it into segments for the smoking article industry without operational breaks.

[0021] At operational level, therefore, the aforementioned method according to this invention, operable preferably through the work island just described, comprises feeding the continuous reinforcing web and feeding the moist, plant-based material. The method comprises making an at least partly multilayer web by combining the moist, plant-based material with the reinforcing web and operating on the multilayer web to remove a substantial quantity of moisture at least from the layer of material of plant origin. The method then comprises forming, from the multilayer web, rod-shaped segments for the smoking article industry. These steps are carried out directly in-process by a single work island, in particular in a continuous process.

[0022] The Applicant has found that making a multilayer web by adding a reinforcing web allows increasing the mechanical tensile strength of the web. Consequently, the web does not break despite the high operating speed in the second machine, thus ensuring the continuity of the production process. This allows coupling the two machines (that is, the primary and secondary steps) in a continuous line (inline), ensuring a direct transition between the two machines and without the need for an intermediate step of winding onto rolls. Adopting such a solution translates as greater efficiency of the production process, in terms of productivity, reduced down time, and optimized operational costs, while at the same time ensuring better dimensional stability and good conditions of the final product.

[0023] The work island and method according to this invention may also include one or more of the technical aspects outlined hereunder.

[0024] According to an aspect, the feed unit for feeding a moist, plant-based material may be configured to make a moist material in the form of a mixture which is like a dough or a moist material in the form of a mixture which is like a slurry.

[0025] The term "dough" denotes a mixture characterized by a low moisture content, generally less than 60% and, more specifically, less than 50% (preferably between 20% and 40%), and a high viscosity, giving the mixture a dense, cohesive and malleable consistency. By contrast, the term "slurry" denotes a mixture with a high moisture content, generally higher than 60% and, more specifically, higher than 70%, causing a significant reduction in viscosity, resulting in a fluid mixture whose consistency is liquid or semiliquid (pourable).

[0026] For a mixture of the first type, the feed unit for feeding a moist, plant-based material may comprise at least one kneader configured to make a moist material in the form of a dough-like mixture. The forming unit comprises at least one pair of laminating rollers configured to press the moist material onto the reinforcing web. Advantageously, the low-moisture mixture reduces energy consumption (especially the energy needed for subsequent drying) and simplifies plant architecture.

[0027] In a first example embodiment, the feed unit for feeding a moist, plant-based material comprises at least one pair of auxiliary laminating rollers configured to convert the moist material in the form of a mixture into a moist material in the form of a continuous layer: in this embodiment, the pair of laminating rollers of the forming unit is configured to combine the moist material in the form of a continuous layer with the reinforcing layer. In other words, in this configuration, the moist, plant-based material, initially in the form of a mixture (dough), is first converted into a uniform, continuous layer using at least one pair of auxiliary laminating rollers. Downstream, the reinforcing web and the moist material in the form of continuous layer converge in the forming unit. Here, a second pair of laminating rollers of the forming unit combines the two elements, pressing them together to form a multilayer web.

[0028] In another example embodiment, the feed unit for feeding a moist, plant-based material is configured to feed the moist material in the form of a mixture directly to the pair of laminating rollers of the forming unit: in this embodiment, the pair of laminating rollers of the forming unit is configured to combine the moist material in the form of a mixture with the reinforcing layer. In other words, in this variant, the moist material in the form of a mixture is fed directly to the pair of laminating rollers of the forming unit without going through intermediate, pre-laminating stages. The main rollers have a twofold function: on the one hand, they compress and shape the plant-based mixture to form a compact layer, and on the other, at the same time, they integrate it with the reinforcing web. The pressure applied by the rollers causes the two materials to adhere to each other, creating a cohesive multilayer web substantially in a single step. Advantageously, this feature eliminates the need for auxiliary components, thus simplifying the production flow and reducing the overall dimensions of the plant.

[0029] For a mixture of the second type, the feed unit for feeding a moist, plant-based material may comprise at least one mixing device configured to make a moist material in the form of a slurry-like mixture: the forming unit may then comprise at least one metering device and / or a spreading device configured to spread the moist material in the form of a slurry on the reinforcing web. In other words, in this configuration, the moist material is made like a fluid suspension and, using a metering device or a spreading system (for example, a smoothing blade or a coated roller), is uniformly distributed on the reinforcing web. Next, during drying, the residual moisture is removed in a controlled manner, thus consolidating the composite structure.

[0030] According to an aspect, depending on the nature of the reinforcing web and in combination with the type of mixture used and the forming process adopted, different multilayer web configurations can be obtained. For example, if the reinforcing web has a structure such as to promote mainly the ability to adhere to the surface, the moist, plant-based material simply adheres and is fixed to the reinforcing web, but nevertheless ensures that the layers are integrated to a certain extent. Alternatively, the moist material may be partly or completely incorporated into the reinforcing web. This method allows obtaining a multilayer web having a "sandwich" structure, where the reinforcing web is interpenetrated by the material of plant origin and integrated in the material of plant origin.

[0031] According to an aspect, whatever the type of multilayer web obtained, the machine for making a continuous multilayer web of the smoking article industry may comprise a cutting and separating unit configured to cut the multilayer web parallel to a feed direction of the multilayer web so as to obtain two or more multilayer sub-webs of predetermined width and also configured to direct at least one of said sub-webs to a respective machine for making rod-shaped segments for the smoking article industry. In other words, the machine for making the multilayer web has a built-in cutting and separating unit designed to cut the multilayer web along its feed direction, so as to obtain two or more sub-webs of calibrated width. Each sub-web may then be directed towards a respective machine for the production of rod-shaped segments, located downstream. This system allows feeding two or more production lines in parallel starting from a single multilayer web, and thus optimizing the overall production capacity.

[0032] According to an aspect, the work island may be configured to temporarily store rolls of multilayer web, in particular rolls of the aforementioned multilayer sub-webs.

[0033] For this purpose, the work island may comprise a temporary storage buffer located downstream of, or built into, the machine for making a multilayer web.

[0034] In an embodiment, the machine for making a multilayer web may comprise a winding unit configured to receive one or more sub-webs from the cutting and separating unit and to wind the one or more sub-webs onto rolls. These rolls, as will become clearer as this description continues, may be transferred into the temporary storage buffer by automatic movement means.

[0035] In another embodiment, the cutting and separating unit is configured to direct at least one or the multilayer sub-webs to the buffer, which comprises a winding unit configured to wind the at least one multilayer sub-web onto rolls.

[0036] In a first example, the temporary storage buffer comprises a winding unit which is also configured to directly store the rolls made.

[0037] In a second example, the temporary storage buffer comprises a winding unit and a storage unit, distinct from the winding unit, where the rolls are stored temporarily after being made in the winding unit.

[0038] In other words, the temporary storage buffer has a cushioning effect between the cutting unit and the machines downstream, absorbing any "rhythmic misalignment" between the steps in the process. The multilayer sub-web intended for storage is wound onto rolls by a motorized winding unit. The rolls thus made are kept temporarily in a dedicated area. This system allows accumulating semi-finished material during peaks in production or programmed interruptions of the machines downstream, thus ensuring process continuity upstream.

[0039] Structurally, the temporary storage buffer may comprise first movement means configured to pick up the rolls from the winding unit and to deposit the rolls in the storage unit, and second movement means configured to pick up the rolls from the storage unit and to feed the rolls to the machine for making rod-shaped segments. The first movement means may be defined by a robotic arm or pushing means. The second movement means may be defined by a robotic arm. In a particularly advantageous embodiment, the first movement means and the second movement means are defined by the same robotic arm.

[0040] In the embodiment in which the winding unit and the storage unit are substantially integral, the first movement means are configured only to direct the sub-web to be wound on a roll to a predetermined winding spool. The buffer may also comprise a control unit configured to drive the movement means.

[0041] The temporary storage buffer may also comprise a plurality of detecting devices, such as, for example, encoders, optical proximity sensors or laser sensors, load sensors, connected to the control unit and configured to monitor operating parameters of the temporary storage buffer: the control unit is thus configured to drive the movement means as a function of the parameters detected.

[0042] The technical purpose and aim specified are substantially achieved by a work island and a method according to claims 18 and 23 and / or one or more of the claims dependent thereon.

[0043] The work island comprises a machine for making a continuous web of the smoking article industry, of known type, based on state-of-the-art technology. The continuous web may be a single-layer web made using known, state-of-the-art methods, or a multilayer web made using a machine which makes a multilayer web as described above.

[0044] The work island comprises a winding unit configured to roll up the web made by the machine for making a web.

[0045] The work island comprises a temporary storage buffer, located downstream of the machine for making a continuous web of the smoking article industry and configured to store a plurality of rolls of the web formed by the winding unit.

[0046] The work island comprises at least one machine for making rod-shaped segments for the smoking article industry, configured to receive one or more stored rolls from the buffer and to operate on the web produced by the machine for making the web so as to make the rod-shaped segments for the smoking article industry. The machine for making rod-shaped segments is therefore operatively located downstream of the temporary storage buffer.

[0047] At operational level, therefore, the aforementioned method according to this invention, operable preferably through the work island just described, firstly comprises making a continuous web for the smoking article industry with the machine for making a continuous web of the smoking article industry. The method secondly comprise winding the web made by the aforesaid machine onto rolls. The method comprises storing the rolls temporarily in the buffer. The method then comprises picking up at least one of the rolls of web from the temporary storage buffer and feeding it to the at least one machine for making rod-shaped segments for the smoking article industry, configured to operate on the web so as to convert it into rod-shaped segments for the smoking article industry. These steps are carried out in a single work island.

[0048] The Applicant has found that providing the temporary storage buffer between the machine for making the continuous web and the machine for making the rod-shaped segments offers significant advantages, whatever the type of web used. First of all, the physical proximity of the two machines, thanks to the buffer between them, eliminates the downtime due to transporting the rolls, thus accelerating material transfer and ensuring smooth transition between the steps of the process. The buffer has a dynamic cushioning effect allowing the machine upstream to work continuously even in the case of temporary shutdowns or speed variations of the machine downstream, thus maintaining production continuity and reducing waste.

[0049] The work island and method according to this invention may also include one or more of the technical aspects outlined hereunder.

[0050] According to an aspect, the winding unit may be an integral part of the machine for making a web or it may be an integral part of the temporary storage buffer.

[0051] In the first embodiment, the machine for making a multilayer web comprises a respective winding unit configured to receive the web made and to wind the web onto rolls.

[0052] In an example, the winding unit is configured to receive the original web made, that is to say, in its original size.

[0053] In another example, the machine for making a continuous multilayer web of the smoking article industry may comprise a cutting and separating unit configured to cut the web parallel to a feed direction of the web so as to obtain two or more sub-webs of predetermined width: in this example, the winding unit is configured to wind the sub-webs onto respective rolls.

[0054] In the second embodiment, the temporary storage buffer comprises a respective winding unit which is configured to receive the web from the machine for making a web and to wind the web onto rolls. As described above, the winding unit may receive a web of original size or a plurality of sub-webs (if the cutting and separating unit is present).

[0055] In an example, the winding unit also defines a storage unit. In other words, the winding unit comprises a plurality of motorized winding spools onto which the web or the sub-web is wound to form the roll. Once formed, the roll is not moved any more until it is picked up and fed to the machine for making rod-shaped segments. The winding unit has a rack-like structure and extends substantially vertically.

[0056] In another example embodiment, the buffer comprises a winding unit and a storage unit, distinct from the winding unit, where the rolls are stored temporarily after being made in the winding unit. In other words, the rolls are firstly made in the winding unit and subsequently transferred to the storage unit, as explained in more detail hereunder. The storage unit has a rack-like structure and extends substantially vertically.

[0057] According to an aspect, the buffer may operate automatically, partly automatically or fully automatically.

[0058] The temporary storage buffer may comprise first movement means configured to pick up the rolls from the winding unit and to deposit the rolls in the storage unit, and second movement means configured to pick up the rolls from the storage unit and to feed the rolls to the machine for making rod-shaped segments. The first movement means may be defined by a robotic arm or pushing means. The second movement means may be defined by a robotic arm. In a particularly advantageous embodiment, the first movement means and the second movement means are defined by the same robotic arm. If the winding unit is an integral part of the storage unit, the first movement means are configured to direct the web or the sub-web to the respective motorized winding spool.

[0059] The buffer may also comprise a control unit configured to drive the movement means.

[0060] The temporary storage buffer may also comprise a plurality of detecting devices, such as, for example, encoders, optical proximity sensors or laser sensors, load sensors, connected to the control unit and configured to monitor operating parameters of the temporary storage buffer: the control unit is thus configured to drive the movement means as a function of the parameters detected.

[0061] The technical purpose and aim specified are substantially achieved by a work island and a method according to claims 25 and 28 and / or one or more of the claims dependent thereon.

[0062] The work island is configured to operate in a continuous process.

[0063] The work island comprises a machine for making a continuous web of the smoking article industry. Preferably, the web is a single-layer web.

[0064] This machine is configured to make the web by laminating a dough-like mixture and then drying it.

[0065] In particular, this machine comprises a kneader, configured to make a dough-like mixture (having a percentage moisture content usually less than 50%), and at least one pair of auxiliary laminating rollers, located downstream of the kneader and configured to laminate the mixture to make the continuous web. This machine comprises a drying unit, located downstream of the at least one auxiliary laminating roller and configured to dry the continuous web.

[0066] The work island comprises at least one machine for making rod-shaped segments for the smoking article industry, connected (preferably directly connected) to the machine for making a web, and configured to form rod-shaped segments for the smoking article industry from that web.

[0067] The machine for making rod-shaped segments for the smoking article industry operates in sequence relative to the machine for making a web of the smoking article industry.

[0068] The machine for making rod-shaped segments for the smoking article industry is configured to receive a continuous web (N) fed to it.

[0069] The Applicant has found that the solution described above has several advantages compared to an alternative solution where the web of the smoking article industry is made from a slurry-like mixture having a liquid consistency and usually having a moisture content of at least 70%. In effect, a work island of this kind would require a drying unit of much larger size compared to the drying unit needed to dry a web obtained from a dough-like mixture, owing to the different percentage content of moisture in the two types of mixture. This aspect, first of all, means that the work island proposed above has a reduced installation footprint and can be installed in the same factory building. Moreover, the drying unit suitable for drying a web made from a slurry-like mixture usually comprises two distinct drying chambers, connected to each other by an intermediate conveyor between them. After passing through the first chamber on a first supporting conveyor, the web is received by the intermediate conveyor, onto which it drops thanks also to detaching / scraping elements which help detach the web from the first supporting conveyor on which the web has been partly dried. From the intermediate conveyor, the web is transferred to a second supporting conveyor which carries it into the second drying chamber. Therefore, it is evident that in the case of a web made from a slurry-like mixture, the configuration of the drying unit involves higher tensile stress for the web, in that the web not only has to travel along a longer path to reach the secondary machine but is also subjected to additional stress when it passes from one part of the drying unit to another.

[0070] Further features of the invention and its advantages are more apparent in the following exemplary, hence non-limiting description of a unit for laminating a continuous layer of plant-based material, in particular of the smoking article industry, according to the invention.

[0071] The description is set out below with reference to the accompanying drawings which are provided solely for purposes of illustration without limiting the scope of the invention and in which: Figure 1 shows a schematic view of a first embodiment of a work island for making rod-shaped segments for the smoking article industry according to this invention; Figure 2 shows a schematic view of a second embodiment of a work island for making rod-shaped segments for the smoking article industry according to this invention; Figure 3 shows a schematic view of a third embodiment of a work island for making rod-shaped segments for the smoking article industry according to this invention; Figure 4 shows a schematic view of a fourth embodiment of a work island for making rod-shaped segments for the smoking article industry according to this invention.

[0072] With reference to the accompanying drawings, the reference numeral 1 denotes a work island for making rod-shaped segments S for the smoking article industry according to this invention. The method for making rod-shaped segments for the smoking article industry, which also forms part of the invention, will be described concurrently with the description of respective embodiments of the work island 1.

[0073] Figure 1 shows a first embodiment of the work island 1.

[0074] The work island 1 comprises a machine 100 for making a continuous multilayer web N of the smoking article industry, configured to make a multilayer web N comprising at least one layer of plant-based reconstituted material and at least one reinforcing layer.

[0075] The machine 100 comprises a feed unit 50 for feeding a continuous reinforcing layer R. In this embodiment, the reinforcing layer R is a layer of paper.

[0076] The machine 100 comprises a feed unit 10 for feeding a moist, plant-based material M. In this embodiment, the feed unit 10 for feeding a moist, plant-based material M comprises at least one kneader 11 configured to make a moist material M in the form of a dough-like mixture.

[0077] In particular, the feed unit 10 for feeding a moist, plant-based material comprises a plurality of pairs of auxiliary laminating rollers 12 configured to convert the moist material M in the form of a mixture into a moist material in the form of a layer.

[0078] The machine 100 comprises a forming unit 20, located downstream of the two feed units 50, 10, and configured to receive and combine said moist, plant-based material M with the reinforcing web R so as to make a continuous web N which is at least partly multilayer. In this embodiment, the forming unit 20 comprises at least one pair of laminating rollers 21 configured to press the moist material M onto the reinforcing web R. In particular, the pair of laminating rollers 21 of the forming unit 20 is configured to combine the moist material M in the form of a continuous layer with the reinforcing layer R.

[0079] The machine 100 comprises a drying unit 30, located downstream of the forming unit 20 and configured to remove a substantial quantity of moisture at least from the layer of material of plant origin.

[0080] In this embodiment, the machine 100 comprises a cutting and separating unit 40, located downstream of the drying unit 30 and configured to cut the multilayer web N parallel to a feed direction of the multilayer web so as to obtain two or more multilayer sub-webs SN of predetermined width, and also configured to direct at least one of the sub-webs SN to a respective machine 200 for making rod-shaped segments S for the smoking article industry.

[0081] The work island 1 thus comprises two respective machines 200 for making rod-shaped segments S for the smoking article industry, connected downstream of the machine 100 for making a multilayer web N, in particular downstream of the cutting and separating unit 30, and configured to form rod-shaped segments S for the smoking article industry from the multilayer web N. The machine 200 for making rod-shaped segments S for the smoking article industry operates in sequence relative to the machine 100 for making a multilayer web N of the smoking article industry.

[0082] Figure 2 shows a second embodiment of the work island 1. This embodiment differs from the previous embodiment in the following aspects.

[0083] Firstly, in this embodiment, the feed unit 10 for feeding a moist, plant-based material M is configured to feed the moist material M in the form of a mixture directly to the pair of laminating rollers 21 of the forming unit 20: the pair of laminating rollers 21 of the forming unit 20 is therefore configured to combine the moist material M in the form of a mixture with the reinforcing layer R, thus simultaneously forming the moist layer and coupling the moist layer to the reinforcing layer R..

[0084] Secondly, the work island 1 comprises a single machine 200 for making rod-shaped segments for the smoking article industry and a temporary storage buffer 300 to which the cutting and separating unit 40 is configured to direct one of the multilayer sub-webs SN. The buffer 300 comprises a winding unit 301 configured to wind the multilayer sub-web SN onto rolls B.

[0085] Figure 3 shows a third embodiment of the work island 1.

[0086] In this embodiment, the work island 1 comprises a machine 100 for making a continuous web of the smoking article industry. The machine 100 is based on known technology and is therefore not described in detail. Preferably, but not necessarily, in this embodiment too, the web N made is a multilayer web.

[0087] The work island 1 comprises a temporary storage buffer 300, located downstream of the machine 100 for making a web N of the smoking article industry and configured to wind the web N onto one or more storage rolls B. In the embodiment illustrated, the machine 100 comprises a cutting and separating unit (not illustrated) configured to cut the multilayer web N parallel to a feed direction of the web so as to obtain two or more sub-webs SN of predetermined width. The sub-webs SN are both fed to the temporary storage buffer 300.

[0088] The work island 1 then comprises a machine 200 for making rod-shaped segments S for the smoking article industry, configured to receive one or more storage rolls B and to operate on the web N made by the machine 100 so as to make the rod-shaped segments S. In other words, at operational level, the machine 200 is located downstream of the temporary storage buffer 300.

[0089] As illustrated in detail in Figure 3, the buffer 300 comprises a winding unit 301 configured to wind each of the multilayer sub-webs SN onto respective rolls B. In other words, in this embodiment, the winding unit 301 is integral with the buffer 300.

[0090] The buffer also comprises a storage unit 302, preferably a rack, configured to store the rolls B.

[0091] The buffer 300 comprises first movement means 303 configured to pick up the rolls B from the winding unit 301 and to deposit the rolls B in the storage unit 302. The buffer 300 comprises second movement means 304 configured to pick up the rolls B from the storage unit 302 and to feed the rolls to the machine 200 for making rod-shaped segments S. In the embodiment illustrated, the first movement means 303 and the second movement means 304 are defined by a single robotic arm configured to perform both functions.

[0092] The buffer 300 comprises a control unit U, configured to drive the movement means 303, 304.

[0093] The temporary storage buffer 300 also comprises a plurality of detecting devices (not illustrated), such as, for example, encoders, optical proximity sensors or laser sensors, load sensors, connected to the control unit and configured to monitor operating parameters of the temporary storage buffer: the control unit U is thus configured to drive the movement means as a function of the parameters detected.

[0094] Figure 4 shows a fourth embodiment of the work island 1.

[0095] In this embodiment, the work island comprises a machine 100 for making a continuous web N of the smoking article industry.

[0096] The machine 100 is configured to make the web N by laminating a dough-like mixture and then drying it.

[0097] In particular, the machine 100 comprises a kneader 11 configured to make a dough-like mixture, and at least one pair of auxiliary laminating rollers 12, located downstream of the kneader 11 and configured to laminate the mixture to make the continuous web N.

[0098] The machine 100 comprises a drying unit 30, located downstream of the at least one pair of auxiliary rollers 12 for drying the web N.

[0099] Preferably, the machine 100 also comprises at least one cutting and separating unit 40 for the web N.

[0100] The machine 100 is clearly configured to feed a continuous web N or continuous sub-webs SN without transverse breaks.

[0101] The work island 1 comprises at least one machine 200 for making rod-shaped segments S for the smoking article industry, connected (preferably directly connected) to the machine 100 for making a web N, and configured to form rod-shaped segments S for the smoking article industry from the web N.

[0102] The machine 200 for making rod-shaped segments S for the smoking article industry operates in sequence relative to the machine 100 for making a web N of the smoking article industry.

[0103] The machine 200 for making rod-shaped segments S for the smoking article industry is configured to receive a continuous web N fed to it.

[0104] Generally speaking, in each of the embodiments described above, the machine 100 for making a web N and the machine 200 for making rod-shaped segments S may be driven so they work substantially at the same operating speed. The expression "operating speed" is used substantially to indicate the productivity, represented in metres of web made / processed per minute (calculated in the longitudinal feed direction of the web). More in detail, in particular for the embodiments in which the machine 100 for making a web N and the machine 200 for making rod-shaped segments S are directly connected, the machines 100, 200 may be driven so they work preferably at an operating speed of between 50 and 100 metres per minute (that is, metres of web made / processed per minute), more preferably between 70 and 85 metres per minute (that is, metres of web made / processed per minute) and still more preferably, 80 metres per minute (that is, metres of web made / processed per minute).

[0105] On the other hand, the presence of the buffer 300, in the embodiments which include it, allows driving the machine 100 for making a web N and the machine 200 for making rod-shaped segments S also at substantially different operating speeds. For example, the machine 100 for making a web N may be driven so it works at an operating speed of between 12 and 40 metres per minute (that is, metres of web made per minute), while the machine 200 for making rod-shaped segments may be driven so it works at an operating speed of between 150 and 300 metres per minute (that is, metres of web processed per minute), preferably between 200 and 250 metres per minute (that is, metres of web processed per minute).

[0106] This invention achieves the preset aims and overcomes the disadvantages of the prior art.

Claims

1. A work island (1) for making rod-shaped segments (S) for the smoking article industry by a continuous process, comprising: - a machine (100) for making a continuous multilayer web (N) of the smoking article industry, configured to make a multilayer web (N) comprising at least one layer of plant-based reconstituted material and at least one reinforcing layer; said machine (100) comprising: - a feed unit (50) for feeding a continuous reinforcing web (R), said reinforcing web (R) being preferably a fibre-based web and / or a web made at least partly of a conductive material; - a feed unit (10) for feeding a moist, plant-based material (M); - a forming unit (20), configured to receive and combine said moist, plant-based material (M) and said reinforcing web (R) so as to make a continuous web (N) which is at least partly multilayer; - a drying unit (30), located downstream of the forming unit (20) and configured to remove a substantial quantity of moisture at least from the layer of material of plant origin; - at least one machine (200) for making rod-shaped segments (S) for the smoking article industry, connected to said machine (100) for making a multilayer web (N), and configured to form rod-shaped segments (S) for the smoking article industry from said multilayer web (N); where said machine (200) for making rod-shaped segments (S) for the smoking article industry operates in sequence relative to said machine (100) for making a multilayer web (N) of the smoking article industry.

2. The work island (1) according to claim 1, wherein said feed unit (10) for feeding a moist, plant-based material (M) comprises at least one kneader (11) configured to make a dough-like mixture, and wherein said forming unit (20) comprises at least one pair of laminating rollers (21) configured to press the moist material onto said reinforcing web (R).

3. The work island (1) according to claim 2, wherein said feed unit (10) for feeding a moist, plant-based material (M) also comprises at least one pair of auxiliary laminating rollers (12) configured to convert said moist material (M) in the form of a mixture into a moist material (M) in the form of a continuous layer, and wherein said pair of laminating rollers (21) of the forming unit (20) is configured to combine said moist material (M) in the form of a continuous layer and said reinforcing web (R).

4. The work island (1) according to claim 2, wherein said feed unit (10) for feeding a moist, plant-based material (M) is disposed and / or configured to feed the moist material (M) in the form of a mixture directly to the pair of laminating rollers (21) of the forming unit (20), and wherein said pair of laminating rollers (21) of the forming unit (20) is configured to combine said moist material (M) in the form of a mixture and said reinforcing web (R).

5. The work island (1) according to claim 1, wherein said feed unit (10) for feeding a moist, plant-based material (M) comprises at least one mixing device configured to make a moist material (M) in the form of a slurry-like mixture, and wherein said forming unit (20) comprises at least one metering device and / or one spreading device configured to apply said moist material (M) in the form of a mixture on said reinforcing web (R).

6. The work island (1) according to any one of the preceding claims, wherein said machine (100) for making a multilayer web (N) comprises a cutting and separating unit (40), located downstream of the drying unit (30) and configured to make one or more longitudinal cuts in said multilayer web (N) so as to obtain two or more multilayer sub-webs (SN) of predetermined width, and also configured to direct at least one of said sub-webs (SN) to a respective machine (200) for making rod-shaped segments (S) for the smoking article industry.

7. The work island (1) according to any one of the preceding claims, comprising a temporary storage buffer (300) configured to support a plurality of rolls of multilayer web (N) and / or of said sub-webs (SN).

8. The work island (1) according to claims 6 and 7, wherein the cutting and separating unit (40) is configured to direct at least one of said multilayer sub-webs (SN) to a winding unit of said machine (100) for making a multilayer web (N) or to the buffer (300), which comprises a winding unit (301) configured to wind said multilayer sub-web (SN) onto a roll (B).

9. A method for making rod-shaped segments (S) for the smoking article industry, in particular operable by a work island (1) according to any one of the preceding claims, comprising the following steps: - feeding a continuous reinforcing web (R), said reinforcing web (R) being a fibre-based web and / or a web made at least partly of a conductive material; - feeding a moist, plant-based material (M); - making a web (N) which is at least partly multilayer by combining said moist, plant-based material (M) and said reinforcing web (R); - operating on said multilayer web (N) to remove a substantial quantity of moisture at least from the layer of material of plant origin; - forming, from said multilayer web (N), rod-shaped segments (S) for the smoking article industry; wherein said steps are carried out directly in-process by a single work island (1), in particular in a continuous process.

10. The method according to claim 9, wherein the step of feeding the moist, plant-based material (M) comprises a sub-step of making a moist material (M) in the form of a dough-like mixture and wherein the step of making the multilayer web (N) comprises using at least one pair of laminating rollers (21) configured to press the moist material (M) onto said reinforcing web (R).

11. The method according to claim 10, wherein the step of feeding the moist, plant-based material (M) also comprises a at least one pair of auxiliary laminating rollers (12) configured to convert the moist material (M) from having the form of a mixture to having the form of a continuous layer and wherein the step of making the multilayer web (N) comprises combining the moist material (M) in the form a layer and the reinforcing web (R) using said pair of laminating rollers (21).

12. The method according to claim 10, wherein the step of feeding the moist, plant-based material (M) is carried out by feeding the moist material (M) in the form of a mixture directly to the pair of laminating rollers (21), and wherein the step of making the multilayer web (N) comprises combining the moist material (M) in the form a layer and the reinforcing web (R) using said pair of laminating rollers (21).

13. The method according to claim 9, wherein the step of feeding the moist, plant-based material (M) comprises a sub-step of making a moist material (M) in the form of a slurry-like mixture and wherein the step of making the multilayer web comprises applying the moist material (M) using at least a metering device and / or a spreading device for spreading the material on the reinforcing web (R).

14. The method according to any one of claims 9 to 13, comprising a step of cutting and separating, wherein the multilayer web (N) is cut parallel to the feed direction to obtain two or more multilayer sub-webs (SN) of predetermined width, and wherein at least one of the sub-webs (SN) is directed to a respective machine (200) for making rod-shaped segments (S) for the smoking article industry.

15. The method according to claim 14, comprising a step of storing temporarily, wherein at least one of the multilayer sub-webs (SN) obtained is directed to a temporary storage buffer (300), which comprises a step of winding said multilayer sub-web (SN) onto a roll (B).

16. The method according to any one of claims 13 to 15, wherein said multilayer web (N) is a two-layer web (N).

17. The method according to any one of claims 13 to 15, wherein said multilayer web (N) is a three-layer web (N), said multilayer web (N) having two outer layers made of reconstituted material of plant origin and an inner layer consisting at least of said reinforcing web (R).

18. A work island (1) for making rod-shaped segments (S) for the smoking article industry, comprising: - a machine (100) for making a continuous web (N) of the smoking article industry; - a winding unit (301) configured to wind said web (N) onto a roll (B); - a temporary storage buffer (300), located downstream of the machine (100) for making a continuous web (N) of the smoking article industry and configured to store a plurality of rolls of said web (N) formed by the winding unit; - at least one machine (200) for making rod-shaped segments (S) for the smoking article industry, configured to receive one or more rolls (B) from said buffer (300) and to operate on the web (N) unwound from said one or more rolls (B) to make a succession of rod-shaped segments (S) for the smoking article industry.

19. The work island (1) according to claim 18, wherein the winding unit (301) is integrated in the temporary storage buffer (300).

20. The work island (1) according to claim 19, wherein said temporary storage buffer (300) comprises: - a storage unit (302), preferably a rack, configured to store the rolls (B); - first movement means (303) configured to pick up the rolls (B) from the winding unit (301) and to deposit the rolls (B) in the storage unit (302); - second movement means (304) configured to pick up the rolls (B) from the storage unit (302) and to feed the rolls to the machine (200) for making rod-shaped segments (S); - a control unit (U), connected to said movement means (303, 304) and configured to drive said movement means (303, 304).

21. The work island (1) according to claim 18, wherein the winding unit (301) is integrated in the machine (100) for making a web (N).

22. The work island (1) according to claim 18, wherein said temporary storage buffer (300) comprises a plurality of detecting devices, such as, for example, encoders, optical proximity sensors or laser sensors, load sensors, connected to the control unit (U) and configured to monitor operating parameters of the temporary storage buffer (300); the control unit (U) being configured to drive the movement means (303, 304) as a function of the parameters detected.

23. A method for making rod-shaped segments (S) for the smoking article industry, in particular operable by a work island (1) according to any one of the preceding claims from 18 to 22, comprising the following steps: - making a continuous web (N) for the smoking article industry using a machine (100) for making a continuous web (N) of the smoking article industry; - winding said web (N) onto one or more rolls (B); - storing said rolls (B) in a temporary storage buffer (300); - picking up at least one of the rolls (B) from the temporary storage buffer (300) and feeding it to a machine (200) for making rod-shaped segments (S) for the smoking article industry, configured to operate on the web (N) so as to make a succession of rod-shaped segments (S) for the smoking article industry; wherein said steps are carried out in a single work island (1).

24. The method according to claim 23, wherein said temporary storage buffer (300) is configured to operate at least partly automatically.

25. A work island (1) for making rod-shaped segments (S) for the smoking article industry by a continuous process, comprising: - a machine (100) for making a continuous web (N) of the smoking article industry; said machine (100) being configured to make said web (N) by laminating a dough-like mixture and then drying it; - at least one machine (200) for making rod-shaped segments (S) for the smoking article industry, connected to said machine (100) for making a web (N), and configured to form rod-shaped segments (S) for the smoking article industry from said web (N); where said machine (200) for making rod-shaped segments (S) for the smoking article industry operates in sequence relative to said machine (100) for making a web (N) of the smoking article industry, said machine (200) for making rod-shaped segments (S) for the smoking article industry being configured to receive a continuous web (N) fed to it.

26. The work island (1) according to claim 25, wherein said machine (100) comprises a kneader (11) configured to make a dough-like mixture, and at least one pair of auxiliary laminating rollers (12), located downstream of the kneader (11) and configured to laminate the mixture to make said continuous web (N).

27. The work island (1) according to claim 25 or 26, wherein said continuous web (N) is a single-layer web.

28. A method for making rod-shaped segments (S) for the smoking article industry, in particular operable by a work island (1) according to any one of the preceding claims from 25 to 27, comprising the following steps: - making a continuous web (N) for the smoking article industry using a machine (100) for making a continuous web (N) of the smoking article industry; said web (N) being made by laminating a dough-like mixture and then drying it; - feeding said continuous web (N) to at least one machine (200) for making rod-shaped segments (S) for the smoking article industry; - forming rod-shaped segments (S) for the smoking article industry from said web (N), using said machine (200) for making rod-shaped segments (S) for the smoking article industry; wherein said steps are carried out directly in-process by a single work island (1), in a continuous process.

29. The method according to claim 28, wherein said continuous web (N) is a single-layer web.

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