Method and apparatus for processing plant-derived materials

Abstract

The present invention provides a method for processing plant-derived material, the method comprising intermittently contacting the plant-derived material with a heated surface to locally heat the material upon said contact, and collecting volatile components released from the plant-derived material. An apparatus for processing the plant-derived material is also provided. The present invention also provides volatile components collected as part of the processing of the plant-derived material, as well as uses of and products containing the components.

Description

Field

[0001] The present invention provides a method for processing plant-derived material. An apparatus for processing plant-derived material is also provided. The present invention also provides volatile components collected as part of the processing of plant-derived material, as well as uses of and products containing the components. Background

[0002] Various methods and devices are known for the thermal treatment of plant-based materials. Heating liberates volatile components of the plant-based material, which are often attractive because they contribute to the aroma and taste of the material. In the course of many known treatment methods, these components are lost. There is also a risk that the thermal treatment may alter the volatile components in a harmful way. Overview

[0003] According to a first aspect of the invention, there is provided a method comprising intermittently contacting plant-derived material with a heated surface to locally heat the material upon said contact, and collecting volatile components released from the plant-derived material.

[0004] In some embodiments, the volatile components are collected in the gas stream, hi some embodiments, the volatile components are trapped and / or extracted.

[0005] In some embodiments, the plant-derived material is selected from the group consisting of tobacco, wood, tea, coffee, cocoa, herbs and spices.

[0006] In some embodiments, the plant-derived material is freshly harvested, dried, cured, or roasted.

[0007] In some embodiments, the plant-derived material is agitated so as to provide intermittent contact with the heated surface.

[0008] In some embodiments, the heated surface has a temperature of at least about 100° C. to about 300° C. prior to contacting the plant-derived material. In some embodiments, the heated surface has a temperature of at least about 120° C. to about 250° C. prior to contacting the plant-derived material, or at least about 150° C. to about 300° C. prior to contacting the plant-derived material.

[0009] In some embodiments, the plant-derived material is heated to a peak temperature of about 120°C to about 230°C by contacting the plant-derived material with a heated surface.

[0010] In some embodiments, the plant-derived material has a moisture content of at least about 5% OV prior to contact with the heated surface.

[0011] In some embodiments, the plant-derived material has a moisture content of about 5 to about 25% OV prior to contacting a heated surface, or has a moisture content of about 12 to about 16% OV prior to contacting a heated surface.

[0012] In some embodiments, the plant-derived material is in intermittent contact with the heated surface for at least about 1 minute to about 180 minutes.

[0013] In some embodiments, the process is a continuous process. In other embodiments, the process is a batch process.

[0014] In some embodiments, the plant-derived material is a tobacco material. In some embodiments, the tobacco material comprises one or more selected from the group consisting of shredded stems, shredded lamina, leaf lamina, minor lamina, stem fibers, short stems, and long stems.

[0015] In some embodiments, the method further comprises applying at least one of the collected volatile components to a substrate.

[0016] In some embodiments, the substrate comprises a plant-derived material that has been treated by intermittent contact with a heated surface.

[0017] According to a second aspect of the invention there is provided an apparatus comprising a heated surface adapted for intermittent contact with plant-based material and means for collecting released volatile components.

[0018] In some embodiments, the apparatus further comprises a means for agitating the plant-derived material. In some embodiments, the means for agitating the plant-derived material comprises at least one of the group consisting of a screw mechanism, a dual screw mechanism, an air stream, and a rotating drum.

[0019] In some embodiments, the heated surface has a temperature of at least about 100° C. to about 300° C. prior to contacting the plant-derived material.

[0020] In some embodiments, the heated surface has a temperature of at least about 120° C. to about 250° C. prior to contacting the plant-derived material, or at least about 150° C. to about 300° C. prior to contacting the plant-derived material.

[0021] In some embodiments, the heating surface is heated by a heating medium, the heating medium being water, oil, steam, electricity, or a combination thereof.

[0022] According to a third aspect of the invention there is provided an extract comprising volatile components collected by the method according to the first aspect of the invention.

[0023] According to a fourth aspect of the present invention, there is provided a composition comprising a substrate and at least one of the collected volatile components.

[0024] In some embodiments, the substrate comprises processed plant-derived material obtained or obtainable by the method according to the first aspect of the present invention.

[0025] According to a fifth aspect of the present invention there is provided a tobacco industry product comprising an extract according to the third aspect of the present invention or a composition according to the fourth aspect.

[0026] According to a sixth aspect of the present invention there is provided the use of collected volatile components obtained or obtainable by a method according to the first aspect of the present invention for the manufacture of a tobacco industry product.

[0027] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0028] [Figure 1a] FIG. 1 illustrates a process flow diagram of an exemplary method. [Figure 1b] FIG. 1 illustrates a process flow diagram of an exemplary method. [Diagram 2] FIG. 1 is an illustration of an apparatus for processing plant-derived material. [Diagram 3] FIG. 1 is a schematic diagram showing the process of plant-derived material passing through the device. Detailed Description

[0029] Many plant-derived materials may be heat-treated for a variety of reasons. In some cases, the material needs to be dried before use or prior to further processing steps.

[0030] Determining the moisture content of plant-derived materials can be important as it can affect the processing characteristics of the material and the properties of the processed products. The terms "moisture" and "moisture content" are commonly used to refer to the moisture content of a material, but in natural products such as plant-derived materials, it is difficult to determine the moisture content. It is therefore desirable to distinguish between "moisture" as moisture content and "moisture" as oven volatiles. Moisture content is defined as the percentage of water contained in the total mass of the solid material. Volatiles are defined as the percentage of volatile components contained in the total mass of the solid material. Volatiles include water and all other volatile compounds. Oven dry mass is the mass remaining after the volatiles are removed by heating. Oven dry mass is expressed as a percentage of the total mass. Oven volatiles (OV) is the mass of volatiles removed.

[0031] Moisture content (oven volatiles) may be measured as the mass lost when the sample is dried for 3 hours ±0.5 minutes in a forced air oven at a controlled temperature of 110° C. ±1° C. After drying, the sample is cooled to room temperature in a desiccator for approximately 30 minutes to allow the sample to cool.

[0032] Unless otherwise noted, moisture content in this specification refers to oven volatiles (OV).

[0033] Various types of drying equipment are known and are typically selected based on the desired moisture content in the plant-derived material after drying and the properties of the plant-derived material to be dried.

[0034] A cased leaf dryer (CLD) is a type of equipment that dries plant-derived material such as leaf tobacco (not cut tobacco) to a very low final moisture content (to about 4%). Leaf tobacco dried using such equipment typically has an initial moisture content of about 28% to about 36%. The drying process involves placing the tobacco on a perforated band. The tobacco is dried by hot air passing through the holes in the band. The band is not directly heated, but may be indirectly heated by hot air passing through the dryer. The tobacco remains in contact with the band during drying, and the temperature of the heated air used to dry tobacco leaves is generally between 80 °C and 170 °C, but mostly between 100 °C and 140 °C. As the hot air is still oxygen-rich, the temperature of the tobacco does not exceed 100 °C, even when the dryer is operating at 170 °C, because the tobacco would ignite in "hot spots".

[0035] Other known types of equipment for drying tobacco and other plant-derived materials include flash tower dryers and fluidized bed dryers. The drying process involves the passage of an air / steam mixture through the dryer, creating turbulence in the flow of the plant material. The bed of these dryers is not heated, instead the air / steam mixture is heated. Fluidized bed dryers are used to dry cut tobacco stems, which tend to have initial moisture contents in the range of about 28-50% OV. Flash tower dryers, including HTD (High Temperature Dryer), HXD (High Expansion Flash Dryer) and air dryers, do not have a bed but similarly rely on a heated air / steam mixture and are primarily used to dry cut tobacco lamina, which may have initial moisture contents in the range of about 20%-36% OV, and occasionally (exceptionally) cut tobacco stems, which have initial moisture contents in the range of about 28%-50% OV. The residence time of the plant-derived material in a flash tower dryer is very short, often just a few seconds. In contrast, plant-based materials may be dried in fluidized bed dryers for a few minutes. The final moisture content of the processed material produced in such equipment is above about 10% OV. In both dryer types, the material reaches temperatures of about 50°C to 100°C.

[0036] A further known type of equipment for drying tobacco and other plant-derived materials is the drum dryer. This type of dryer utilizes a heated metal drum, and the drying process can be thought of as a mixture of air drying and drying with a heated surface. The rotation of the drum tumbles the material, creating a level of turbulence in the material and air. The metal surface is heated, but only to a temperature of about 60-130°C. Tobacco processed using this type of equipment has a final moisture content of greater than 10%. Typically, the moisture content of the starting material depends on the type of material being dried. Cut tobacco lamina has an initial moisture content between 20% and 26%, while cut tobacco stems have an initial moisture content of 28%-50%. After 3-4 minutes (for cut stems) or 4-7 minutes (for cut lamina) of processing time in the drum dryer, the processed tobacco has a moisture content of 12-15%.

[0037] All of these dryers exhaust gases generated during the heating process, which include water and volatiles that are released as a result of heating.

[0038] In contrast to these known drying processes and apparatus, an important aspect of the method and apparatus for processing plant-derived material of the present invention involves the combination of intermittently contacting the plant-derived material with a heated surface to locally heat the material and collecting volatile components released from the plant-derived material due to the localized heating.

[0039] It has been found that exposing plant-derived materials to a hot surface not only dries the material to a very low moisture content, but also reduces the moisture content (based on oven volatiles), meaning that the plant-derived material releases volatile components.

[0040] These volatile components include aroma and flavor components important to some plant-derived materials, the loss of which can have detrimental effects on the treated material. Alternatively, or in addition, the volatiles may be valuable in their own right. For these reasons, the methods disclosed herein collect the volatile components.

[0041] The collected volatile components may be reincorporated into the treated plant-derived material if desired. In some embodiments, the collected volatile components may undergo further processing before being added back into the treated material. For example, the collected volatile components may be separated and only selected components added back. Alternatively, or in addition, the volatile components may be concentrated before being added back. Additionally, in some embodiments, other components (not released from the plant-derived material) may be added to the collected volatile components before being added back into the treated plant-derived material.

[0042] In other embodiments, the collected volatile components form a new product separate from the treated plant-derived material, which may be gaseous, liquid, or solid depending on the components present and their intended use.

[0043] Volatile components may be trapped using established techniques, such as freezing or cold trapping, or may be trapped using a substrate for subsequent liquid extraction. In some embodiments, the gas formed as a result of the thermal treatment of the plant-derived material is sucked out of the treatment chamber, for example by a vacuum pump system. The gas stream is then cooled to condense the vapor. In some embodiments, the gas may be sublimated, bypassing the liquid phase and changing the gas molecules directly into a solid (crystalline) phase. The cold trap may be cooled by any available means, such as mechanical refrigeration, dry ice, liquid nitrogen, etc.

[0044] The processing of some plant-derived materials by the methods of some embodiments of the present invention results in chemical changes to the materials, and these chemical changes are not only found in the treated plant-derived materials, but also in the volatile components that are released.

[0045] The trapped volatile components may, in some embodiments, be used to create a perfume mixture that is perceived to give the impression of the perfume of the plant-derived material from which the mixture is derived.

[0046] The trapped volatile components can be used to produce an extract in one or more suitable forms, including liquid and solid forms. In some embodiments, the trapped volatile components are condensed into a liquid form. In some embodiments, the liquid may then be converted into a solid form, such as a powder. In other embodiments, the volatile components are deposited directly into a solid form.

[0047] The extract may contain the volatile components in a concentrated form (ie, a more concentrated form than they were present in the plant material from which they were derived).

[0048] In some embodiments, the extract generated from the trapped volatile components is added or applied to a carrier or substrate. In some embodiments, the carrier or substrate can be selected to enhance or control the release of flavoring ingredients. In some embodiments, the carrier or substrate can be selected from one or more of fibrous materials (such as filter materials, e.g., cellulose acetate tow), sheet materials, adsorbent materials (such as adsorbent carbon, activated carbon, silica gel, alumina, polymeric resins, zeolites, sepiolites, and mixtures thereof), and plant materials (such as tobacco materials).

[0049] In some embodiments, the extract is applied to the treated plant-derived material from which the trapped volatile components originate. Thus, a method comprising intermittently contacting the plant-derived material with a heated surface and collecting the volatile components released from the plant-derived material may further comprise generating a flavor mixture from the volatile components and applying this (e.g., after cooling) to the treated plant-derived material.

[0050] The extracts produced from the trapped volatile components can be used in a variety of ways and in a variety of products. For example, it may be desirable to use these extracts in tobacco industry products. Such products include, for example, tobacco heating products and e-cigarettes, and the extracts can be used to change or improve the flavor of the aerosol produced by such devices. When the plant-derived material is tobacco, the extracts produced from the volatile components released by the plant-derived material can include tobacco flavors and aromas. The use of such extracts in tobacco heating products or e-cigarettes can provide a sensation similar to or reminiscent of traditional cigarettes.

[0051] Additionally or alternatively, the processed plant-derived material produced by the method disclosed herein can be used in tobacco industry products.In some embodiments, the processed plant-derived material can be a material that is produced as a result of intermittent contact with a heated surface that results in the release of volatile components.In other embodiments, the processed plant-derived material can include one or more additives.In some embodiments, the processed plant-derived material can be combined with one or more flavor mixtures, optionally with an extract produced from the processing of the plant-derived material itself.

[0052] As used herein, the term "plant-derived material" includes any part of a plant and any associated by-products, such as leaves, stems, roots, seeds, and one or more of the foregoing parts.

[0053] The plant-derived material may be any plant material, and in some embodiments, is a plant that has a desirable flavor or aroma. Suitable plant materials include plant materials such as wood, tea, coffee, cocoa, herbs, spices, and tobacco of any type, style, or variety.

[0054] In some embodiments, the plant-derived material is wood. Almost any wood can be used. The volatile components collected after heat treatment of this material can have a "flame-cured" flavor. The flavor mixture generated from these volatile components can be added to tobacco, for example tobacco used in combustible smoking articles such as cigarettes, or tobacco for tobacco heating devices, to generate a "flame-cured" taste without the need for flame-cured tobacco. This is advantageous because flame-curing of tobacco can lead to undesirable increases in polycyclic aromatic hydrocarbon (PAH) levels in the tobacco and / or in the aerosol generated by heating or burning the tobacco.

[0055] As used herein, the term "tobacco material" includes any part, such as the leaves or stems, of any plant of the genus Nicotiana, and any associated by-products. The tobacco material used in the present invention is preferably of the species Nicotiana tabacum.

[0056] In some embodiments, the tobacco starting material (i.e., the tobacco material prior to being processed using the methods disclosed herein) is one or more selected from the group consisting of shredded stems, shredded lamina, leaf lamina, minor lamina, stem fibers, short stems, and long stems.

[0057] Any type, style and / or variety of tobacco may be processed. Examples of tobacco that may be used include, but are not limited to, Virginia, Burley, Oriental, Comum, Amarelinho, and Maryland tobacco, as well as blends of any of these types. Those skilled in the art will recognize that processing different types, styles and / or varieties may result in tobacco having different organoleptic characteristics.

[0058] Tobacco or other plant-derived material may be pre-treated according to known practices.

[0059] The tobacco material to be treated may include and / or consist of post-cured tobacco. As used herein, the term "post-cured tobacco" refers to tobacco that has been cured but has not undergone any further treatment processes that alter the taste and / or aroma of the tobacco material. Post-cured tobacco may be blended with other styles, varieties and / or types. Post-cured tobacco does not include or consist of cut rag tobacco.

[0060] Alternatively, or in addition, the tobacco material being processed may comprise and / or consist of tobacco that has been processed to the stage performed in a green-leaf boning (GLT) plant. The tobacco material being processed may include re-graded tobacco, green-blend tobacco, conditioned tobacco, de-stemmed or de-boned tobacco (or non-whole), cured tobacco, and / or packaged tobacco.

[0061] In some embodiments, the tobacco material comprises a laminar tobacco material. For example, the tobacco can comprise between about 70% and 100% laminar material. In some embodiments, the tobacco material comprises at most about 50%, at most about 60%, at most about 70%, at most about 80%, at most about 90%, or at most about 95% laminar tobacco material. In some embodiments, the tobacco material comprises at most 100% laminar tobacco material. In other words, the tobacco material may be substantially entirely, or entirely, composed of laminar tobacco material.

[0062] Alternatively, or in addition, the tobacco material can comprise at least about 50%, at least about 60%, at least about 70%, at least about 80%, at least about 90%, or at least about 95% laminar tobacco material.

[0063] When the tobacco material comprises a lamina tobacco material, the lamina may be in whole leaf form. In some embodiments, the tobacco material comprises cured whole leaf tobacco. In some embodiments, the tobacco material substantially comprises cured whole leaf tobacco. In some embodiments, the tobacco material consists essentially of cured whole leaf tobacco. In some embodiments, the tobacco material does not comprise cut rag tobacco. In some embodiments, the tobacco is cut lamina and / or expanded tobacco (such as dry ice expanded tobacco (DIET)).

[0064] In some embodiments, the tobacco material comprises stem tobacco material. The tobacco can comprise between about 90% and 100% stem material.

[0065] The tobacco material may comprise up to about 50%, up to about 60%, up to about 70%, up to about 80%, up to about 90%, or up to about 95% stem tobacco material. In some embodiments, the tobacco material comprises up to 100% stem tobacco material. In other words, the tobacco material may be substantially entirely, or entirely, composed of stem tobacco material.

[0066] Alternatively, or in addition, the tobacco material can comprise at least about 50%, at least about 60%, at least about 70%, at least about 80%, at least about 90%, or at least about 95% stem tobacco material.

[0067] In some embodiments, the tobacco material comprises a blend of lamina and stems.

[0068] In some embodiments, the tobacco material comprises expanded tobacco, such as dry ice expanded tobacco (DIET).

[0069] Intermittent contact of the plant-derived material with the heated surface exposes the plant-derived material to repeated short periods of intense heat. In some embodiments, this intermittent contact can be achieved by stirring the plant-derived material. The temperature of the heated surface, and therefore the temperature to which the plant-derived material is exposed, is significantly higher than about 100° C., and in some embodiments, is at least about 150° C. Thus, intermittent contact is important to ensure that the plant-derived material does not burn as a result of continuous exposure to such high temperature surfaces for long periods of time.

[0070] In some embodiments, intermittent contact of the plant-derived material with a heated surface results in burning or scorching of the plant-derived material, a result of exposure to sudden intense heat, which also has a drying effect, but results in a treatment of the plant-derived material different from the gentle drying processes known in the prior art.

[0071] In some embodiments, the oxygen level surrounding the plant-derived material during processing can be reduced. This is believed to have the effect of reducing the risk of "hot spots" forming as a result of exposure to heated surfaces and reducing the risk of burning the plant-derived material. This reduced oxygen level therefore allows the plant-derived material to be processed at higher temperatures than prior art methods and apparatus. In some embodiments, the oxygen level is reduced by applying steam.

[0072] Without wishing to be bound by any particular theory, it is hypothesized that the process is divided into two stages. In the first stage, the plant-derived material is dried by exposing it to heat, which removes volatile components, including water, in a manner similar to steam distillation. In the second stage, an effect referred to herein as "scorching" occurs. It is during this second stage that the main chemical changes in the plant-derived material appear to occur. These chemical changes may result in the release of additional volatiles from the material.

[0073] It is hypothesized that the brief contact of plant-derived materials, particularly tobacco materials, with a heated surface and localized torching of the tobacco can increase the Maillard and caramelization reaction products, many of which are known to contribute to desirable sensory properties. This is described in more detail in the Examples below. The Maillard reaction is a chemical reaction between amino acids and sugars, which are present in the starting material but are reduced in the treated material. The Maillard reaction is a non-enzymatic reaction that typically occurs at temperatures of about 140-165°C. In addition to the pleasing effect that the Maillard reaction products have on sensory properties, the reaction also causes the material to brown. It has been observed that materials treated according to embodiments of the present invention have a darker brown color than the starting material.

[0074] In some embodiments, the methods of processing plant-derived materials described herein produce treated materials with enhanced flavor or aroma properties (compared to the flavor properties of plant-derived materials that are not processed or that are processed using only conventional methods). As used herein, the term "enhancement" or "enhancement" used in the context of flavor or aroma properties means that there is an improvement or improvement in taste or aroma, or the quality of the taste or aroma. This may include, but does not necessarily include, an intensification of taste or aroma. In embodiments where collected volatile components are added to the treated material, the taste and aroma properties may be enhanced. If the collected volatile components are concentrated or contain additional components, the taste or aroma properties of the treated material may be enhanced.

[0075] In the case of tobacco materials and some other plant-derived materials, the treatment may improve the sensory properties of the treated material. As used herein, the sensory properties of a tobacco material may refer to the sensory properties of the tobacco material itself, for example, when used orally by a consumer. Additionally or alternatively, it may refer to the sensory properties of the smoke produced by burning the tobacco material or the vapour produced by heating the tobacco material. In some embodiments, the treated tobacco material results in a tobacco product comprising the tobacco material having desirable sensory properties when the tobacco product is used or consumed.

[0076] In some embodiments, the temperature of the heated surface ranges from about 100° C. to about 300° C. In some embodiments, the temperature is at least about 105° C., 110° C., 115° C., 120° C., 125° C., 130° C., 135° C., 140° C., 145° C., 150° C., 155° C., 160° C., 165° C., 170° C., 175° C., 180° C., 185° C., 190° C., 195° C., or at least about 200° C. In some embodiments, the temperature of the heated surface is up to about 295° C., 290° C., 285° C., 280° C., 275° C., 270° C., 265° C., 260° C., 255° C., 250° C., 245° C., 240° C., 235° C., 230° C., 225° C., 220° C., 215° C., 210° C., 205° C., or up to about 200° C. In some embodiments, the heated surface has a temperature of at least about 120° C. to about 250° C., or at least about 150° C. to about 300° C.

[0077] When the temperature of the heated surface is mentioned, it is referred to herein as the temperature before contact with the plant-derived material. This is because the contact with the plant-derived material and the drying process may lead to cooling of the heated surface. Thus, the exact temperature of the heated surface during the drying process depends on how much "drying work" is performed. For example, in the initial phase of water evaporation from the plant-derived material, more energy is utilized, and therefore the heated surface is cooled more strongly. Thus, the temperature of the heated surface before contact with the plant-derived material can be easily and accurately determined.

[0078] In some embodiments, the temperature of the heated surface is controlled to minimize significant changes during the treatment process, for example, a feedback mechanism can be used to heat the surface when the temperature drops as a result of processing the plant-derived material to ensure that the temperature remains within an acceptable range.

[0079] In some embodiments, it is appropriate to adjust the temperature of the heating surface according to the type of plant-derived material to be treated.One reason why this is appropriate is that different plant-derived materials have different initial moisture contents, and therefore the treatment involves the removal of different amounts of moisture and volatiles.Also, different plant-derived materials have different physical properties.For example, leaves have a more brittle structure, whereas wood is more dense and sturdy.

[0080] In some embodiments, the heating surface is a metal, such as stainless steel, or any other suitable steel or metal type with sufficient heat transfer properties. In other embodiments, the heating surface is made of any material with sufficient heat transfer properties that can be heated to the temperatures used in the methods described herein. For example, a ceramic surface can be used.

[0081] The heating surface may be indirectly heated by a heating medium, such as a heating medium selected from the group consisting of oil, water, or steam. In some embodiments, thermal oil is the preferred heating medium. Alternatively, or in addition, the heating surface may be directly heated. In some embodiments, the heating surface is heated electrically.

[0082] In some embodiments, when treating more brittle materials such as leaves, the heated surface has a temperature before contacting the plant-derived material in the range of about 170° C. to about 190° C. In some embodiments, when treating more sturdy materials such as wood, the heated surface has a temperature before contacting the plant-derived material above 200° C., optionally in the range of about 220° C. to about 250° C.

[0083] Repeated intermittent contact of the plant-derived material with the heated surface heats the plant-derived material. The high temperature of the heated surface significantly increases the temperature of the plant-derived material. In some embodiments, the treatment method results in an increase in the temperature of the plant-derived material to a peak temperature in the range of about 120°C to about 230°C. In some embodiments, the peak temperature of the plant-derived material is at least about 125°C, 130°C, 135°C, 140°C, 145°C, 150°C, 155°C, 160°C, 165°C, 170°C, 175°C, 180°C, 185°C, 190°C, 195°C, 200°C, 205°C, 210°C, 215°C, or at least about 220°C. In some embodiments, the peak temperature of the plant-derived material is up to about 225° C., 220° C., 215° C., 210° C., 195° C., 190° C., 185° C., 180° C., 175° C., 170° C., 165° C., 160° C., 155° C., 150° C., 145° C., 140° C., 135° C., 130° C., or up to about 125° C. The temperature of the plant-derived material may be measured using a suitable measurement device, such as an infrared measurement or an electrical resistance thermometer.

[0084] In some embodiments, the plant-derived material is heated under an inert atmosphere.

[0085] In some embodiments, an inert gas such as nitrogen, saturated water vapor, carbon dioxide or mixtures thereof is added to the equipment to control oxygen levels and thereby promote desired chemical reactions during processing.

[0086] In other embodiments, the plant-derived material is heated in an oxidizing atmosphere.

[0087] In some embodiments, the heat treatment of the plant-derived material has a drying effect, and the moisture content of the plant-derived material is reduced. For example, the treated plant-derived material can have a moisture content of 0% to about 10% oven volatiles (OV). In other words, the treated plant-derived material has a moisture content of about 10% OV or less. In some embodiments, the moisture content of the treated plant-derived material is 9.5%, 9%, 8.5%, 8%, 7.5%, 7%, 6.5%, 6%, 5.5%, 5%, 4.5%, 4%, 3.5%, 3%, 2.5%, 2%, 1.5%, 1%, or about 0.5% OV or less. In some embodiments, the treated plant-derived material has a moisture content of about 2% OV or less.

[0088] In some embodiments, the starting material (before heat treatment) has a moisture content of at least about 5% OV. In some embodiments, the moisture content of the plant-derived starting material is at least about 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, or at least about 24% OV. In some embodiments, the moisture content of the plant-derived starting material is about 25%, 24%, 23%, 22%, 21%, 20%, 19%, 18%, 17%, 16%, 15%, 14%, 13%, 12%, 11%, 10%, 9%, 8%, 7%, or less than about 6% OV. In some embodiments, the plant-derived starting material has a moisture content of at least about 5% to about 25% OV, or at least about 5% to about 20% OV. In some embodiments, the plant-derived starting material has a moisture content of at least about 12% to about 16% OV.

[0089] Thus, in some embodiments, the starting material used in the methods of the present invention has a moisture content that means that the plant-derived material is already dried. In some embodiments, the main purpose of this plant-derived treatment is not to further reduce the moisture content of the plant-derived starting material, but to bring about physical and chemical changes in the plant-derived material as a result of scorching caused by brief contact with the high temperature of a heated surface. In some embodiments, this effect is achieved without burning or substantially burning the plant-derived material as a result of contact with the heated surface.

[0090] In some embodiments, the moisture content of the plant-derived material may be adjusted during the treatment process by adding moisture. The moisture may be introduced into the plant-derived material in the form of water or steam during treatment. The moisture may be sprayed onto the plant-derived material while it is in intermittent contact with a heated surface.

[0091] In some embodiments, the introduction of this moisture increases the moisture content of the plant-derived material by 2% to 5% OV, hi some embodiments, moisture is introduced at different locations throughout the process.

[0092] As the plant-derived material is moistened during processing, the moisture content drops again when the moistened plant-derived material comes into contact with the heated surface. The method can include multiple additions of moisture such that the moisture content of the plant-derived material repeatedly rises and falls during processing.

[0093] In some embodiments, the treatment involves repeatedly and intermittently contacting the plant-derived material with one or more heated surfaces over a treatment period of at least about 1 minute to about 15 minutes. In some embodiments, the period during which the plant-derived material is intermittently contacted with the heated surface is at least about 1 minute, 2 minutes, 3 minutes, 4 minutes, 5 minutes, 6 minutes, 7 minutes, 8 minutes, 9 minutes, 10 minutes, 11 minutes, 12 minutes, 13 minutes, or at least about 14 minutes. In some embodiments, the period during which the plant-derived material is intermittently contacted with the heated surface is at most about 14 minutes, 13 minutes, 12 minutes, 11 minutes, 10 minutes, 9 minutes, 8 minutes, 7 minutes, 6 minutes, 5 minutes, 4 minutes, 3 minutes, or at most about 2 minutes. In some embodiments, the plant-derived material is contacted with the heated surface for a total time of at least about 2 minutes to about 10 minutes, or at least about 2.5 minutes to about 5 minutes.

[0094] The intermittent contact may involve direct and continuous contact of the plant-derived material with the heated surface for up to about 5 seconds, hi some embodiments, the average length of the period or periods of direct and continuous contact is from about 0.1 seconds to about 3 seconds.

[0095] As used herein, intermittent contact of the plant-derived material with the heated surface means that any portion of the plant-derived material is in direct contact with the heated surface only temporarily. In some embodiments, this means that the plant-derived material is moved relative to the heated surface to prevent the plant-derived material from remaining stationary in a particular position in contact with the heated surface for an extended period of time and / or to ensure that the same portion of the plant-derived material is not in direct contact with the heated surface for an extended period of time. Prolonged contact of the same portion of the plant-derived material with the heated surface can result in combustion that adversely affects the physical and chemical properties of the plant-derived material and can result in the generation and collection of undesirable volatile components.

[0096] In some embodiments, the method includes agitating the plant-derived material as it is processed. In some embodiments, an apparatus is provided that includes a means for agitating the plant-derived material.

[0097] In some embodiments, it is preferred to agitate the plant-derived material by tumbling the plant-derived material, which can be achieved, for example, by picking up the plant-derived material to be treated, lifting it up and then dropping it, causing a tumbling movement of the plant-derived material.

[0098] In some embodiments, the movement of the plant-derived material can be caused by a mechanism that includes one or more screws. In such an arrangement, the screw includes a helical surface that surrounds a rotating shaft, the helical surface configured to pick up the plant-derived material. As the shaft rotates, the helical surface picks up at least a portion of the plant-derived material to be processed. This plant-derived material is carried and lifted by the rotating helical surface, and then falls (by gravity) off the screw due to the rotation of the screw. In some embodiments, the one or more screws can be arranged to agitate the plant-derived material as well as move it through the processing chamber. Such an arrangement allows the plant-derived material to be processed continuously. In some embodiments, the helical surface and / or shaft of the screw can be heated to provide a heated surface that is used to process the plant-derived material. When two screws are used to move the plant-derived material, the screws can be arranged in parallel and are arranged to contact and move all of the plant-derived material to be processed. In some embodiments, the screw can include an additional paddle to assist in picking up and transporting the plant-derived material. These paddles may also be heated surfaces used to process plant-derived materials.

[0099] In other embodiments, the plant-derived material may be agitated in a rotating drum. The interior of the drum may be a chamber in which the plant-derived material is processed. The plant-derived material is inside the drum and is picked up and lifted from the bottom of the drum as the drum rotates. Picking up the plant-derived material may be facilitated by the drum having an inner surface that can maintain contact with the plant-derived material, for example by having a rough surface or paddle-like protrusions that scoop up the plant-derived material. As the drum rotates, the plant-derived material in contact with the inner surface of the drum is lifted by the rotation of the drum until it falls (by gravity) away from the drum wall and back to the bottom of the drum. This results in tumbling and mixing of the plant-derived material. The unevenness of the inner surface of the drum helps to control the time that the plant-derived material remains in contact with the drum wall. This unevenness can also be used to facilitate the tumbling movement of the plant-derived material so that it does not remain in contact with the drum wall as it falls (slides back down the wall). The speed of rotation also affects the tumbling movement, as does the orientation of the axis of rotation. In some embodiments, the inner surface of the drum may be a heated surface used to process the plant-derived material. The drum may rotate about a horizontal or substantially horizontal axis. In other embodiments, rotation about an inclined axis allows the plant-derived material to maintain contact with the drum inner surface for a longer period and also allows the plant-derived material to move longitudinally. Additionally or alternatively, longitudinal movement of the plant-derived material by rotation of the drum may be achieved by providing the inner surface of the drum with appropriately positioned and / or angled protrusions.

[0100] In other embodiments, the plant-derived material may be agitated by the air flow, e.g., the plant-derived material is picked up and moved by the air flow.

[0101] In some embodiments, the plant-derived material is not agitated by the flow of air through the device. In some embodiments, the apparatus for processing plant-derived material does not include a means for blowing air through the apparatus to agitate the plant-derived material.

[0102] In some embodiments, the process is a continuous process, for example, plant-derived starting material is continuously fed into the apparatus, processed, and exits the apparatus as processed plant-derived material, in another embodiment, the process is a batch process, where a batch of plant-derived starting material is fed into the apparatus and processed to produce a batch of processed plant-derived material, which is removed before a new batch is processed.

[0103] In some embodiments, after treatment, the treated plant-derived material can be conditioned. For example, in some embodiments, moisture can be added to the treated plant-derived material. In some embodiments, the addition of moisture is accomplished by exposing the treated plant-derived material to water and / or steam. In some embodiments, the moisture content is increased to greater than about 10% OV, or from about 10 to about 20% OV.

[0104] In some embodiments, after processing, the processed plant-derived material can be cooled. In some embodiments, cooling can involve the use of a cooling belt where ambient or cooled air passes through a layer of the processed plant-derived material. In other embodiments, the plant-derived material can be cooled by any one or more of the following steps: settling, passing through a cooling cylinder, air lift, cooling by a fluidized bed, etc.

[0105] The flow charts shown in Figures 1a and 1b summarize exemplary steps for processing plant-derived material. The plant-derived starting material may optionally undergo pre-processing. If the material is tobacco material, the pre-processing may be, for example, a conventional primary manufacturing (PMD) process, which may include, for example, conditioning the raw stem, followed by one or more of rolling, shredding and expansion / drying and mixing. In some embodiments, the pre-processing of the lamina may include slicing, conditioning, casing (optional), shredding, drying, cooling and mixing.

[0106] The moisture content of the plant-derived starting material may be, for example, about 14.5% OV. The starting material is fed into a processing device and processed by intermittent contact with heated surfaces. During processing, the plant-derived material is agitated and intermittent contact with heated surfaces occurs. Processing reduces the moisture content to 0% OV. Once processing of the plant-derived material by intermittent contact with heated surfaces is complete, the processed plant-derived material can optionally be subjected to conditioning. In the illustrated process, conditioning involves adding water or steam to the processed plant-derived material to increase the moisture content, for example, to the region of about 14.5% OV.

[0107] The process parameters are gentle enough that the treated plant-derived material maintains some or all of its physical properties. For example, the plant-derived material after treatment remains sufficiently intact to allow handling and / or processing. If the material is a tobacco material, this may mean that the treated tobacco is suitable for incorporation into tobacco-containing products, such as smoking articles. This allows the treated plant-derived material to be handled according to standard processes in the same way as conventional plant-derived material that has not been subjected to the processing described herein.

[0108] Detailed illustrations of an apparatus suitable for carrying out embodiments of the methods described herein are shown in Figures 2 and 3. In this embodiment, the apparatus 1 includes two screws 2 of a dual screw configuration. This configuration would mean that any portion of the plant-derived material may only be in contact with the heated surface for periods of the order of a few seconds at a time as a result of the agitation or turbulence generated by the screws of the apparatus.

[0109] Plant-derived material 8 is processed in an apparatus 1 that includes a transfer screw 2 that includes a helical surface 3 and a shaft 4, which moves the plant-derived material through a processing chamber 7 of the apparatus 1. The screw 2 rotates, and the shaft 4 of the screw 2 is rotated by a drive mechanism 11 that includes a motor.

[0110] Plant-derived starting material enters the treatment chamber 7 through an inlet 5 and a rotating screw picks up the plant-derived material and tumbles it through the treatment chamber towards an outlet 6 .

[0111] More specifically, a mass 8 of plant-derived material enters the treatment chamber 7 through the inlet 5. As the screw 2 rotates, the plant-derived material is picked up and some of the plant-derived material directly contacts the helical surface 3 and possibly the shaft 4 of the screw 2. The plant-derived material is pulled, lifted and dropped by the screw 2 as it is transported and tumbled through the treatment chamber 7. The plant-derived material lifted as a result of the rotating screw(es) subsequently falls into the mass 8 of plant-derived material being transported through the chamber 7, the mass being constantly mixed and moving such that different parts of the mass contact the screw 2 at different times.

[0112] In the illustrated embodiment, the surface of the screw 2 is heated and intermittently contacted with the plant-derived material according to the method for treating the material.

[0113] The screw 2 has a metal surface which is heated by a heating medium which is fed into the device 1 via a heating medium pipe 10. In the embodiment shown, the heating medium is thermal oil which is heated to the desired temperature.

[0114] Only a portion of the plant-derived material being processed is in direct contact with the heated surface at a time. As the plant-derived material is transported, it is tumbling and mixed, creating agitation or turbulence of the plant-derived material and the necessary intermittent contact with the heated surface(s). Individual contact times may be no more than a few seconds at a time. The flow dynamics of the plant-derived material ensure that the entire mass is guided by the screw geometry and processed homogeneously.

[0115] In the illustrated apparatus, the treatment chamber can be divided into different temperature zones 9. The temperature zones 9 represent different parts of the screw, which can be heated separately. Thus, the apparatus can be configured to have surfaces that are heated to different temperatures. In some embodiments, it may be desirable to control the drying and baking stages of the treatment by exposing the plant-derived material to heated surfaces having different temperatures at different points in the treatment process.

[0116] The extract comprising the volatile components collected by the method disclosed herein can be incorporated into tobacco industry products. In some embodiments, the extract can be applied to a substrate for incorporation into the product. A composition comprising a substrate and at least one volatile component collected by the method disclosed herein may be provided. Such a composition can be used in tobacco industry products. In some embodiments, the substrate can comprise a processed plant-derived material, such as a plant-derived material processed according to the method disclosed herein.

[0117] Tobacco industry products refer to any goods manufactured by or sold by the tobacco industry, typically including: a) cigarettes, cigarillos, cigars, pipe tobacco, or roll-your-own tobacco (whether based on tobacco, tobacco derivatives, puffed tobacco, reconstituted tobacco, or tobacco substitutes); b) non-smoking products that incorporate tobacco, tobacco derivatives, puffed tobacco, reconstituted tobacco, or tobacco substitutes such as snuff, snus, hard tobacco, and heat-not-burn (HnB) products; and c) other nicotine delivery systems such as inhalers, aerosol generating devices including e-cigarettes, lozenges, gum, etc. This list is not intended to be exclusive, but merely indicative of the range of products manufactured and sold by the tobacco industry.

[0118] The extracts, compositions and treated plant-derived materials disclosed herein may be incorporated into smoking articles. As used herein, the term "smoking article" includes smokable products such as cigarettes, cigars and cigarillos, whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes, as well as non-combustion heating products. In some embodiments, the extracts, compositions and / or treated plant-derived materials may be incorporated into smoking articles in combination with the tobacco contained in such products. Alternatively, the extracts, compositions and / or treated plant-derived materials may replace the tobacco contained in such products. In some embodiments, the extracts are applied to tobacco or other materials used to generate aerosol in smoking articles.

[0119] The extracts, compositions and treated plant-derived materials, such as treated tobacco materials, may be included in hand-rolled and / or pipe tobacco.

[0120] The extracts, compositions and processed plant-derived materials, such as processed tobacco materials, can be incorporated into smokeless tobacco products. In this specification, "smokeless tobacco product" is used to refer to any tobacco product that is not for combustion. Smokeless tobacco products include any smokeless tobacco product designed to be placed in the mouth of a user for a limited period of time where there is contact between the user's saliva and the product. In some embodiments, the extracts, compositions and / or processed plant-derived materials can be incorporated into smoking articles in combination with tobacco contained in such products. Alternatively, the extracts, compositions and / or processed plant-derived materials can replace tobacco contained in such products.

[0121] The extracts, compositions and treated plant-derived materials may be blended with one or more tobacco materials prior to incorporation into a smoking article or smokeless tobacco product, or prior to use in hand-rolled or pipe tobacco.

[0122] When both the extract produced from the trapped volatile components and the treated plant-derived material are incorporated into the same tobacco industry product, they may be incorporated separately or may be combined, and when introduced separately, the extract and the treated plant-derived material may be incorporated into different parts of the product.

[0123] In some embodiments, the extract (containing the volatile components released from the plant-derived material) may be included in a filter, a smoking article mouthpiece, a consumable part for use with a THP device, and a part for a tobacco industry product, such as an e-liquid or an e-liquid reservoir. The liquid extract may be encapsulated, for example, to produce a flavoring that is released on demand. In some embodiments, the extract is encapsulated in a spherical capsule or other form of capsule, and the capsule may be incorporated into any tobacco industry product, such as a cigarette filter or a mouthpiece for a THP product. EXAMPLES

[0124] The method according to the invention was carried out on tobacco material, namely Cut Expanded Stem (CES) with an (initial) moisture content of 14.5% OV. A mass of tobacco particles was used as input material and was processed by the method using the apparatus shown in Figures 2 and 3.

[0125] The method can be described as exposing particles of tobacco (stem) to a hot metal surface for several seconds before the individual particles "fall" back into the entire mass of tobacco material being treated.

[0126] The residence time of the mass of tobacco particles in the device (and therefore the processing time) is between 1 and 5 minutes. The heated metal surface is heated by a jacket which, like the screw, is heated, and synthetic oil is passed through the heated surface to bring it to the desired temperature.

[0127] Three different temperature scenarios were tested: 230°C, 240°C and 250°C. This means that the temperature of the heating medium (oil) used to heat the heating surfaces was set to these temperatures. This results in different temperatures in different parts of the device.

[0128] The values ​​and parameters shown in Table 1 below reflect the individual temperatures throughout the treatment process when the heating medium (oil) temperature was set at 250°C.

[0129] [Table 1]

[0130] In the experiments, tobacco was treated in a process with a residence time (or treatment period) of about 2-3 minutes and a treatment rate of about 50 kg / h of tobacco material at chopped stem moisture content of about 14.5% OV.

[0131] The process can be divided into two distinct phases. During the first phase, the stalk particles lose moisture. If the temperature of the heating medium (oil) is 250°C, after about 1 minute the moisture content of the stalk is 0% OV. The second phase takes place during the remaining processing time, the effect of which is called "searing". It is during this second phase that the main changes take place.

[0132] Table 2 compares the chemical composition of untreated tobacco and tobacco treated in devices with different heating medium temperatures.

[0133] [Table 2]

[0134] As can be seen from Table 2, the nicotine content of the treated tobacco is reduced by more than 50% at a heating medium temperature of 250°C, and the sum of sugars and ammonia is reduced by more than 80%. The increase in chloride content reflects the total loss of organic matter, and the significant increase in the loading value indicates a change in the cellular structure of the treated tobacco.

[0135] The data demonstrates that tobacco materials undergo significant changes during processing.

[0136] These changes have been shown to lead to changes in the organoleptic properties of the processed material that are discernible in the smoke produced when the treated tobacco is burned, for example, in a cigarette. The organoleptic properties of this smoke have been described in very positive terms by expert smokers, indicating that tobacco processing produces treated materials with beneficial and desirable properties, both in terms of the reduction of some undesirable tobacco constituents and improved organoleptic properties.

[0137] Furthermore, these changes represent some of the volatile components that are collected according to the methods disclosed herein.

[0138] One of these components is nicotine, which is volatilized during the heat treatment and collected.

[0139] Further components include volatile flavour and aroma compounds contained in the tobacco material, which are evaporated during heat treatment.

[0140] Further components may include volatile products of the observed Maillard and caramelization reactions.

[0141] To address various problems and advance the art, the entire disclosure illustrates various embodiments in which the claimed invention may be practiced, providing superior methods, apparatus, and processed tobacco materials and extracts thereof. The advantages and features of the disclosure are only representative samples of embodiments and are not exhaustive and / or exclusive. The advantages and features are presented only to aid in the understanding and teaching of the claimed features. It is to be understood that the advantages, embodiments, examples, features, features, structures, and / or other aspects of the disclosure are not to be construed as limitations to the disclosure as defined by the claims or to the equivalents of the claims, and that other embodiments may be utilized and changes may be made without departing from the scope and / or spirit of the disclosure. Various embodiments may suitably include, consist of, or consist essentially of various combinations of the disclosed elements, components, features, parts, steps, means, etc. In addition, the disclosure includes other inventions not currently claimed but which may be claimed in the future.

Claims

1. intermittently contacting the plant-derived material with a heated surface to locally heat the material upon said contact; collecting volatile components emitted from said plant-derived material; A method comprising:

2. The method of claim 1 , wherein the volatile components are collected in a gas stream.

3. 3. The method of claim 1 or 2, wherein the volatile components are trapped and / or extracted.

4. 3. The method of claim 1 or 2, wherein the plant-derived material is selected from the group consisting of tobacco, wood, tea, coffee, cocoa, herbs and spices.

5. 3. The method of claim 1 or 2, wherein the plant-derived material is freshly harvested, dried, cured, or roasted.

6. 3. The method of claim 1 or 2, wherein the plant-derived material is agitated so as to be in intermittent contact with the heated surface.

7. 3. The method of claim 1 or 2, wherein the heated surface has a temperature of at least 100°C to 300°C before contacting the plant-derived material.

8. 8. The method of claim 7, wherein the heated surface has a temperature of at least 120°C to 250°C before contacting the plant-derived material, or has a temperature of at least 150°C to 300°C before contacting the plant-derived material.

9. 3. The method of claim 1 or 2, wherein the plant-derived material is heated to a peak temperature of from 120°C to 230°C by contacting the plant-derived material with the heated surface.

10. 3. The method of claim 1 or 2, wherein the plant-derived material has a moisture content of at least 5% OV before contacting the heated surface.

11. 11. The method of claim 10, wherein the plant-derived material has a moisture content of 5-25% OV prior to contacting the heated surface, or has a moisture content of 12-16% OV prior to contacting the heated surface.

12. 3. The method of claim 1 or 2, wherein the plant-derived material is in intermittent contact with the heated surface for at least 1 minute to 180 minutes.

13. 3. The process of claim 1 or 2, which is a continuous process.

14. 3. The process according to claim 1 or 2, which is a batch process.

15. 3. The method of claim 1 or 2, wherein the plant-derived material is tobacco material.

16. 16. The method of claim 15, wherein the tobacco material comprises one or more selected from the group consisting of shredded stem, shredded lamina, leaf lamina, minor lamina, stem fiber, short stem, and long stem.

17. The method of claim 1 or 2, further comprising applying at least one of the collected volatile components to a substrate.

18. 18. The method of claim 17, wherein the substrate comprises the plant-derived material that has been treated by intermittent contact with the heated surface.

19. An apparatus comprising a heated surface adapted to be in intermittent contact with plant-derived material, and means for collecting liberated volatile components.

20. 20. The apparatus of claim 19, further comprising means for agitating the plant-derived material.

21. 21. The apparatus of claim 20, wherein the means for agitating the plant-derived material comprises at least one of the group consisting of a screw mechanism, a dual screw mechanism, an airflow, and a rotating drum.

22. 22. An apparatus according to any one of claims 19 to 21, wherein the heated surface has a temperature of at least 100°C to 300°C before contacting the plant-derived material.

23. 23. The apparatus of claim 22, wherein the heated surface has a temperature of at least 120°C to 250°C before contacting the plant-derived material, or has a temperature of at least 150°C to 300°C before contacting the plant-derived material.

24. 22. The apparatus of any one of claims 19 to 21, wherein the heating surface is heated by a heating medium, the heating medium being water, oil, steam, electricity, or a combination thereof.

25. An extract comprising volatile components collected by the method of claim 1 or 2.

26. A composition comprising a substrate and at least one of the collected volatile components.

27. 27. The composition of claim 26, wherein the substrate comprises a processed plant-derived material obtained or obtainable by the method of claim 1 or 2.

28. A tobacco industry product comprising an extract according to claim 25.

29. A tobacco industry product comprising the composition of claim 26.

30. 29. The tobacco industry product of claim 28, wherein the extract is provided in a consumable part of a smoking article.

31. 29. The tobacco industry product of claim 28, wherein the extract is provided to an aerosol-generating component of a tobacco heating device.

32. 29. The tobacco industry product of claim 28, wherein the extract is provided as a liquid for use in an aerosol generating device.

33. 10. Use of collected volatile components obtained or obtainable by the method according to claim 1 or 2 for the manufacture of tobacco industry products.

Images