Method for producing a plant-derived sheet
By determining and adjusting water content based on moisture levels in plant-derived materials, the method addresses issues of variability and inefficiency in plant-derived sheet production, achieving uniformity and reduced energy consumption.
Patent Information
- Application Number
- JP2024561841
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2022-07-26
- Filing Date
- 2023-07-20
- Publication Date
- 2025-07-25
AI Technical Summary
Existing methods for manufacturing plant-derived sheets face challenges due to variations in properties between different batches of plant-derived materials, leading to difficult mixing, time-consuming drying, high energy consumption, and machinery wear from abrasive powders.
A method involving determining the moisture content of plant-derived powder materials, calculating the amount of water based on this content to form a slurry with a uniform water content, and using a cellulose-based sheet former to facilitate easier and faster drying, employing detectors and flow controllers to manage moisture levels.
This approach results in more uniform slurry handling and drying, reducing machinery wear and energy consumption, while ensuring consistent quality across different batches.
Smart Images
Figure 2025523740000001_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to a method for manufacturing a plant-derived sheet. The present invention further relates to a facility configured to manufacture a plant-derived sheet.
Background Art
[0002] Plant-derived materials such as tobacco are natural products and often exhibit large differences in their properties between different batches. Mixing these plant-derived materials with a sheet-forming agent such as cellulose and water is used to produce a slurry for manufacturing a sheet of the plant-derived material. This mixing process is often very difficult and time-consuming due to the variation in properties between different batches of the plant-derived material. Drying the slurry is often very energy-consuming and time-consuming. Furthermore, the long-term handling of the plant-derived material in powder form can cause significant wear of the machinery due to the abrasive nature of the powder particles.
Summary of the Invention
Problems to be Solved by the Invention
[0003] It would be desirable to provide a method for manufacturing a plant-derived sheet that provides a solution that is easy to handle. Furthermore, it would be desirable to provide a method for manufacturing a plant-derived sheet that enables easy and rapid drying of the slurry for manufacturing the plant-derived sheet. Furthermore, it would be desirable to provide a method for manufacturing a plant-derived sheet that consumes less energy.
Means for Solving the Problems
[0004] According to one embodiment of the present invention, a method for manufacturing a plant-derived material sheet is provided. The method may include providing a plant-derived powder material and a cellulose-based sheet former. The method may further include determining the moisture content of the plant-derived material. The method may include mixing the plant-derived powder material, the cellulose-based sheet former, and an amount of water to form a slurry. The method may further include drying the slurry to form a plant-derived sheet. The amount of water added for slurry formation may be calculated based on the determined moisture content of the plant-derived powder material.
[0005] Another embodiment of the present invention provides a method for manufacturing a plant-derived material sheet. The method includes providing a plant-derived powder material and a cellulose-based sheet former. The method also includes determining the moisture content of the plant-derived material. The method includes mixing the plant-derived powder material, the cellulose-based sheet former, and an amount of water to form a slurry. The method further includes drying the slurry to form a plant-derived sheet. The amount of water added for slurry formation is calculated based on the determined moisture content of the plant-derived powder material.
[0006] Such methods may provide an easier way to dry the slurry to form the plant-derived sheet. This may be due to a more uniform water content of the slurry taking into account the moisture content of the plant-derived powder material. This method may produce slurries with a more uniform water content among different batches of plant-derived powder materials having different moisture contents. This may simplify the handling of the slurry during the manufacture of the plant-derived material sheet. This may reduce the handling time of the machine during drying of the slurry. This may reduce the wear of the machine.
[0007] The moisture content of the plant-derived powder material may specifically be the water content of the plant-derived powder material. This moisture content may vary among different batches of the plant-derived powder material. These different water contents may prevent more uniform handling of the plant-derived powder material during the production of the plant-derived material sheet. The method of the present invention may make it possible to take these different water contents of different batches into account when generating a slurry having a more uniform water content.
[0008] The slurry may have a designated target moisture content range. The amount of water added for slurry formation may be calculated such that the slurry reaches a water content within the designated target moisture content range.
[0009] This may make it possible for different batches of the slurry to be within the same designated target moisture content range, despite the different moisture contents of the plant-derived materials. This may facilitate more uniform handling and drying of the slurry for forming the plant-derived sheet.
[0010] The designated target moisture content range of the slurry may be 55 wt% to 85 wt% water, based on the total weight of the slurry. Preferably, the target moisture content range of the slurry may be 60 wt% to 80 wt% water, based on the total weight of the slurry.
[0011] Taking into account the moisture content of the plant-derived powder material, it may be easy to achieve such a designated target moisture content range. Such a designated target moisture content range of the slurry may enable more uniform and easier drying of the slurry for forming the plant-derived sheet.
[0012] A destined target water content of 55 weight percent to 85 weight percent may reduce the appearance of defects in the plant-derived sheet that may occur when the water content falls below the lower limit of 55 weight percent. Similarly, water contents outside this destined target water content may result in a reduction in the tensile strength of the plant-derived sheet and may also complicate the handling of the plant-derived sheet.
[0013] A plant material moisture detector may be employed to determine the moisture content of the plant-derived material.
[0014] The plant-derived powder material may be dispersed on a conveyor belt. The radiation emitted from the plant material moisture detector may be positioned on one side of the conveyor belt, and the radiation receiver of the plant material moisture detector may be positioned on the opposite side of the conveyor belt. This may enable the radiation of the plant material moisture detector to pass through the plant-derived powder material.
[0015] This may enable the conveyance of the plant-derived powder material on the conveyor belt while simultaneously determining the moisture content of the plant-derived material.
[0016] The plant material moisture detector may be one of a microwave detector or an infrared detector. Preferably, the plant material moisture detector may be a microwave detector.
[0017] The microwave detector may include a transmitting antenna and a receiving antenna. The transmitting antenna may emit microwave radiation, and the receiving antenna may receive the microwave radiation transmitted from the transmitting antenna through the plant-derived powder. The plant-derived powder material may be disposed between the transmitting antenna and the receiving antenna of the microwave detector and may also be conveyed on the conveyor belt.
[0018] This may enable the conveyance of plant-derived powder materials for slurry formation. This may enable a simple determination of the moisture content of the plant-derived powder materials while the plant-derived powder materials are being conveyed on a conveyor belt.
[0019] The microwave detector may be a commercially available microwave detector, the MicroPolar LB 567 / LB 568 Microwave Moisture Analyser, from Berthold Technologies GmbH & Co. KG.
[0020] The plant-derived powder materials may include one or both of tobacco powder and hemp powder. Preferably, the plant-derived powder materials may include tobacco powder. The plant-derived powder materials may be tobacco powder, and the material sheet may be a sheet of an aerosol-forming substrate.
[0021] As used herein, the term "aerosol-forming substrate" relates to a substrate having the ability to release one or more volatile compounds capable of forming an aerosol. Such volatile compounds may be released by heating the aerosol-forming substrate. Advantageously, the aerosol-forming substrate may be part of an aerosol-generating article or a smoking article.
[0022] The aerosol-forming substrate may include a solid aerosol-forming substrate. The aerosol-forming substrate may include both solid and liquid components. The aerosol-forming substrate may include a tobacco-containing material containing volatile tobacco flavor compounds released from the substrate upon heating. The aerosol-forming substrate may include a non-tobacco material. The aerosol-forming substrate may include an aerosol former that facilitates the formation of a high-density stable aerosol. Examples of suitable aerosol formers are glycerin and propylene glycol.
[0023] The aerosol-forming substrate may be a solid aerosol-forming substrate. In some embodiments, the solid aerosol-forming substrate contains one or more of the leaves of herbs, tobacco leaves, fragments of tobacco leaf veins, reconstituted tobacco, homogenized tobacco, extruded tobacco, cast leaf tobacco, and expanded tobacco, and may include one or more of powders, granules, pellets, fragments, spaghetti, shreds, or sheets. The solid aerosol-forming substrate may be in a loose form or provided in a suitable container or cartridge. Optionally, the solid aerosol-forming substrate may contain additional tobacco or non-tobacco volatile flavor compounds released upon heating of the substrate. The solid aerosol-forming substrate may also contain, for example, capsules containing additional tobacco or non-tobacco volatile flavor compounds, and such capsules may melt during heating of the solid aerosol-forming substrate.
[0024] As used herein, "homogenized tobacco" refers to a material formed by aggregating particulate tobacco. The homogenized tobacco may be in the form of a sheet. The homogenized tobacco material may have an aerosol former content of more than 5% on a dry weight basis. Alternatively, the homogenized tobacco material may have an aerosol former content of 5 wt% to 30 wt% on a dry weight basis. The sheet of homogenized tobacco material may be formed by aggregating particulate tobacco obtained by grinding one or both of the lamina of the tobacco leaf and the stem of the tobacco leaf, or by combining them in another way. Alternatively, or additionally, the sheet of homogenized tobacco material may contain one or more of, for example, tobacco dust, tobacco fines, and other particulate tobacco by-products formed during the processing, handling, and shipping of tobacco. The sheet of homogenized tobacco material may contain one or more inherent binders (i.e., tobacco endogenous binders), one or more external binders (i.e., tobacco exogenous binders), or a combination thereof to assist in the aggregation of particulate tobacco. Alternatively, or additionally, the sheet of homogenized tobacco material may contain other additives including, but not limited to, tobacco and non-tobacco fibers, aerosol formers, humectants, plasticizers, flavorants, fillers, aqueous and non-aqueous solvents, and combinations thereof.
[0025] In a particularly preferred embodiment, the aerosol-forming substrate comprises an assembly of crimped sheets of homogenized tobacco material. As used herein, the term "crimped sheet" means a sheet having a plurality of substantially parallel ridges or undulations. Preferably, when the aerosol-generating article is assembled, the substantially parallel ridges or undulations extend along or parallel to the longitudinal axis of the aerosol-generating article. This advantageously facilitates the assembly of the crimped sheets of homogenized tobacco material to form the aerosol-forming substrate. However, of course, the crimped sheets of homogenized tobacco material for inclusion in the aerosol-generating article may alternatively or additionally have a plurality of substantially parallel ridges or undulations arranged at an acute or obtuse angle to the longitudinal axis of the aerosol-generating article when the aerosol-generating article is assembled. In certain embodiments, the aerosol-forming substrate may comprise an assembly of sheets of homogenized tobacco material that are substantially evenly textured over substantially the entire surface thereof. For example, the aerosol-forming substrate may comprise an assembly of crimped sheets of homogenized tobacco material that include a plurality of substantially parallel ridges or undulations that are substantially evenly spaced across the width of the sheet.
[0026] The aerosol-forming substrate may be used within an aerosol-generating article. The aerosol-generating article may be used together with an aerosol-generating device. The aerosol-generating device may comprise a cavity configured to receive the aerosol-generating article. The aerosol-generating device may comprise a heating element configured to heat the aerosol-generating article received within the cavity. The aerosol-generating device of the present invention may be configured to heat the aerosol-forming substrate to a temperature below the combustion temperature of the aerosol-forming substrate but above the temperature at which one or more volatile compounds of the aerosol-forming substrate are released to form an inhalable aerosol.
[0027] The plant-derived powder material, preferably tobacco powder, may have an average particle size of 20 micrometers to 200 micrometers, preferably an average particle size of 50 micrometers to 100 micrometers. The average particle size may be determined by laser scattering. The average particle size of the plant-derived powder material may be adjusted to the assigned average particle size range by grinding with a mill. The average particle size of the plant-derived powder material may be adjusted before forming a slurry.
[0028] This may simplify the formation of the slurry. This may provide a more homogeneous slurry.
[0029] The average particle size of the plant-derived powder material may be determined before determining the moisture content of the plant-derived material. The average particle size of the plant-derived powder material may affect the moisture content of the plant-derived powder material. Therefore, the average particle size of the plant-derived powder material may be adjusted to the assigned average particle size range of 20 micrometers to 200 micrometers before determining the moisture content.
[0030] When determining the average particle size of the plant-derived powder material, a particle size sensor may be employed. The particle size sensor may be a laser scattering particle size distribution analyzer such as Horiba LA-950.
[0031] A water flow controller may be employed. The flow controller may control the amount of water added for slurry formation based on the determined moisture content of the plant-derived powder material.
[0032] This may provide an easy way to control the amount of water added for slurry formation.
[0033] An open control loop system may be employed. The open control loop system may adjust the pump speed of the flow controller based on the determined moisture content of the plant-derived powder material. This may enable the flow controller to control the amount of water added to form the slurry.
[0034] The cellulose-based sheet former may contain cellulose fibers. Preferably, a water / cellulose fiber pulp is prepared and then the pulp is mixed with the plant-derived powder material. The water / cellulose pulp may contain cellulose fibers having an average length of 0.2 millimeters to 4 millimeters. Preferably, the average length of the cellulose fibers may be 1 millimeter to about 3 millimeters. Preferably, the cellulose fibers are softwood fibers.
[0035] The water cellulose fiber pulp may have a cellulose fiber concentration of 3 weight percent to 5 weight percent of the total weight of the pulp before being added to the slurry. The total amount of cellulose fibers in the slurry after mixing the pulp with water and the plant-derived powder material is 1 weight percent to 3 weight percent, preferably 1.2 weight percent to 2.4 weight percent of the dry weight of the slurry.
[0036] The slurry may be dried to form a plant-derived sheet, and the plant-derived sheet may have a moisture content of 7 percent to 15 percent of the dry weight of the sheet. Preferably, the plant-derived sheet may be dried to have a moisture content of 8 percent to 12 percent of the dry weight of the sheet.
[0037] The slurry may be prepared in a slurry tank. Thereafter, the slurry may be transferred to a casting box. This may enable casting the slurry by a casting knife on a movable conveyor belt. The conveyor belt may be made of a heat-conductive material, specifically steel. After drying, a continuous plant-derived material sheet with a thickness of 500 micrometers to 700 micrometers may be formed. When the plant-derived powder material contains tobacco powder, the plant-derived material sheet can be a continuous sheet of tobacco cast leaves. These tobacco cast leaf sheets can be wound onto a bobbin and can be further processed to produce an aerosol-generating article containing the tobacco cast leaf sheet as part of an aerosol-forming substrate.
[0038] Instead of forming a tobacco cast leaf sheet, a sheet of a gel-like material containing tobacco may be formed in the same way.
[0039] Drying may be performed by subjecting the slurry disposed on the conveyor belt to drying air in a drying device. Additionally, steam may be provided from below the conveyor belt to dry the plant-derived material sheet in a more uniform manner. The slurry may be conveyed on the conveyor belt through the drying device. The temperature of the drying air may be from 90 degrees Celsius to 140 degrees Celsius. In one embodiment, the drying device may comprise different drying segments. The temperature of the drying air, the flow rate of the drying air, and the flow rate distribution of the drying air may be independently controlled within different drying segments of the drying device. The flow rate of the drying air in the drying device may be from 80 kilograms per hour to 300 kilograms per hour. The length of the drying device may be several hundred meters.
[0040] This may enable a long drying process of the slurry while passing through the drying device on the conveyor belt. This may enable a controlled moisture reduction at a low speed and may result in a plant-derived sheet.
[0041] This may enable the reduction of the moisture content of the slurry in a controlled manner without subjecting the plant-derived material sheet formed from the slurry to excessive temperature or moisture differences.
[0042] To form the slurry, one or both of a thickening agent and an aerosol former may be added. The thickening agent may include guar. The aerosol former is any suitable known compound or mixture of compounds that facilitates the formation of a high-density and stable aerosol during use and is substantially resistant to thermal decomposition at the operating temperature of the system. Suitable aerosol formers are well known in the art and include polyhydric alcohols (such as triethylene glycol, 1,3-butanediol, glycerin), esters of polyhydric alcohols (such as glycerol monoacetate, diacetate, or triacetate), and aliphatic esters of monocarboxylic acids, dicarboxylic acids, or polycarboxylic acids (such as dimethyl dodecanedioate, dimethyl tetradecanedioate), but are not limited thereto. The aerosol former may be a polyhydric alcohol or a mixture thereof (such as triethylene glycol, 1,3-butanediol, glycerin). The aerosol former may be propylene glycol. The aerosol former may include both glycerin and propylene glycol. Preferably, the aerosol former may include one or more of triethylene glycol, 1,3-butanediol, and glycerin.
[0043] An exemplary slurry composition may include 70 to 78 weight percent water and 17 to 22 weight percent plant-derived powder (specifically tobacco powder). This exemplary slurry composition may further include 3 to 6 weight percent glycerin as an aerosol former. Cellulose fibers may be added in an amount of 0.5 to 4 weight percent. An optional thickening agent may be present in an amount of 0 to 1 weight percent. All weight percent ranges shown are based on the total weight of the exemplary slurry composition.
[0044] The slurry may have a targeted water content range. The sum of the determined water content of the plant-derived powder material and the amount of water added for slurry formation may result in a water content of the slurry that falls within the targeted water content range.
[0045] Another embodiment of the method of the present invention may also include a method step of determining the water content of the cellulose-based sheet former. In this case, the sum of the determined water content of the plant-derived powder material, the amount of water added for slurry formation, and the water content of the cellulose-based sheet former may result in a water content of the slurry that falls within the targeted water content range.
[0046] In this embodiment of the method of the present invention, when determining the total amount of water added for slurry formation, not only the water content of the plant-derived powder material but also the water content of the cellulose-based sheet former may be taken into consideration. This may provide a way to more accurately adjust the added water so that it falls within the targeted water content range.
[0047] In another embodiment of the method of the present invention, the water content of one or both of the thickener and the aerosol former may be determined. In this case, the sum of the determined water content of the plant-derived powder material, the amount of water added for slurry formation, the water content of the cellulose-based sheet former, and one or both of the water contents of the thickener and the aerosol former may result in a final water content of the slurry that falls within the targeted water content range.
[0048] In this embodiment of the method of the present invention, the water contents of the aerosol former, the thickener, and the cellulose-based sheet former may be determined together with the water content of the plant-derived powder material and taken into consideration when calculating the amount of water added for slurry formation.
[0049] This may provide a way to more accurately adjust the final water content of the formed slurry.
[0050] The water content of the cellulose-based sheet former at the aerosol-forming end of the thickener may be determined in the same manner as the water content of the plant-derived powder material. Specifically, to determine the water content of the cellulose-based sheet former, a cellulose moisture detector such as a microwave detector or an infrared detector may be employed.
[0051] Specifically, to prepare the water / cellulose pulp described above, a cellulose fiber feeding and preparation line may be employed. The cellulose fiber feeding and preparation line may include a cellulose conveyor belt for transporting raw cellulose fiber materials such as boards, sheets, or fluffy fibers to a pulper to prepare the water / cellulose pulp. The cellulose moisture detector may be present on the cellulose conveyor belt. The cellulose moisture detector may be configured to determine the water content of the raw cellulose fiber material. The cellulose fiber feeding and preparation line may further include a water line configured to introduce water into the pulper. The flow rate of the water passing through the water line may be controlled by a cellulose flow controller. The cellulose flow controller may be configured to receive data on the water content of the raw cellulose fiber material from the cellulose moisture detector. The cellulose flow controller may adjust the pump speed taking into account the water content of the raw cellulose fiber material and the water content of the plant-derived powder material to prepare the water / cellulose pulp. Then, this water / cellulose pulp may be mixed with the plant-derived powder material to prepare the final slurry. Therefore, the water content of the water / cellulose pulp will also affect the final water content of the prepared slurry.
[0052] The step of mixing water and cellulose fibers may continue for 20 to 60 minutes. The temperature inside the pulper may be between 15°C and 40°C. The storage time of the water / cellulose pulp before being mixed with the plant-derived powder material may be between 0.1 day and 7 days.
[0053] Preferably, the water / cellulose pulp may be mixed with additional water before being mixed with the plant-derived powder material. This mixing step of the water / cellulose pulp and the additional water may continue for about 120 to 180 minutes. The temperature during mixing may be from 15°C to 40°C, more preferably from 18°C to 25°C.
[0054] The weight percentage of water in the slurry containing the plant-derived powder material, the cellulose-based sheet former, the thickener, and the aerosol former, particularly the final water content range, may be calculated as follows.
[0055] Weight percentage of water in the slurry = [amount of water added to the slurry + water content of cellulose + water content of aerosol former + water content of thickener + water content of plant-derived powder material] / [(amount of thickener + water content of thickener)+(amount of aerosol former + water content of aerosol former)+(amount of plant-derived material + water content of plant-derived material)+amount of water added to the slurry].
[0056] Another embodiment of the present invention provides a facility configured to manufacture a plant-derived material sheet. The facility may include a mixing tank containing a stirrer. The mixing tank may be configured to mix the plant-derived powder material and the cellulose-based sheet former to form a slurry. The facility may include a plant material moisture detector configured to determine the moisture content of the plant-derived powder material. The facility may also include a water flow controller. The water flow controller may be configured to control the flow rate of water to the mixing tank. The water flow controller may be connected to a water pipe. The water pipe may be configured to convey water to a slurry container to form a slurry. The water flow controller may be further configured to provide a certain amount of water to the mixing tank for slurry formation. The amount of water may be calculated based on the determined moisture content of the plant-derived powder material. The facility may include a drying device for drying the slurry to form a plant-derived sheet.
[0057] A further embodiment of the present invention provides a facility configured to produce a plant-derived material sheet. The facility includes a mixing tank containing a stirrer. The mixing tank is configured to mix a plant-derived powder material and a cellulose-based sheet forming agent to form a slurry. The facility further includes a plant material moisture detector. The plant material moisture detector is configured to determine the moisture content of the plant-derived powder material. The facility also includes a water flow controller. The water flow controller is configured to provide water to the mixing tank. The water flow controller is further configured to provide a certain amount of water to the mixing tank for slurry formation, and the amount of water is calculated based on the determined moisture content of the plant-derived powder material. The facility also includes a drying device for drying the slurry to form a plant-derived sheet.
[0058] Such a facility may be configured to perform a method for forming a plant-derived material sheet as discussed herein. This facility may be able to easily control the amount of water added for slurry formation via the water flow controller.
[0059] The facility may further include an open-loop control system. The open-loop control system may be configured to adjust the pump speed of the flow controller based on the determined moisture content of the plant-derived powder material.
[0060] The facility may include a data processing unit. The data processing unit may include a module for communicating with the plant material moisture detector. The data processing unit may include a module for calculating the amount of water added for slurry formation based on the determined moisture content of the plant-derived material. The data processing unit may include at least a part of the control system.
[0061] This may facilitate the addition of an appropriate amount of water for slurry formation based on the determined moisture content of the plant-derived powder material.
[0062] The slurry may have a targeted water content range. An open-loop control system may be configured to provide such an amount of water to the mixing tank, so that the sum of the determined moisture content of the plant-derived powder material and the amount of water added for slurry formation results in a slurry water content that falls within the target water range.
[0063] Such equipment may be able to easily take into account the determined moisture content of the plant-derived powder material when calculating the amount of water added for slurry formation so that the water content of the slurry is within the targeted water content range.
[0064] The equipment may also include a cellulose moisture detector configured to determine the moisture content of the cellulose-based sheet former. Then, the open-loop control system of the equipment may be configured to provide such an amount of water to the mixing tank so that the sum of the determined moisture content of the plant-derived powder material, the determined moisture content of the cellulose-based sheet former, and the amount of water added for slurry formation results in a slurry water content that falls within the targeted water content range.
[0065] This equipment may also additionally consider the moisture content of the cellulose-based sheet former when calculating the amount of water added for slurry formation.
[0066] The equipment may also include one or both of a thickener moisture detector and an aerosol former moisture detector configured to determine the moisture content of one or both of the thickener and the aerosol former.
[0067] Then, the open-loop control system of the equipment may be configured to provide such an amount of water to the mixing tank so that the sum of the determined moisture content of the plant-derived powder material, the determined moisture content of the cellulose-based sheet former, one or both of the moisture contents of the thickener and the aerosol former, and the amount of water added for slurry formation results in a slurry water content that falls within the targeted water content range.
[0068] Such equipment may be configured to take into account the moisture content of all the major components of the slurry when calculating the amount of water added for slurry formation.
[0069] The following is a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more of the features of any other example, embodiment, or aspect described herein.
[0070] Example E1: A method for manufacturing a plant-derived material sheet, comprising: - providing a plant-derived powder material and a cellulose-based sheet former; - determining the moisture content of the plant-derived material; - mixing the plant-derived powder material, the cellulose-based sheet former, and an amount of water to form a slurry; - drying the slurry to form a plant-derived sheet, - wherein the amount of water added for slurry formation is calculated based on the determined moisture content of the plant-derived powder material. Example E2: The method according to Example E1, wherein the slurry has a target moisture content range assigned thereto, and the amount of water added for slurry formation is calculated such that the moisture content within the target moisture content range assigned to the slurry is reached. Example E3: The method according to any one of Examples E1 to E2, wherein a plant material moisture detector is employed to determine the moisture content of the plant-derived material, preferably the plant material moisture detector is one of a microwave detector or an infrared detector. Example E4: The method according to Example E3, wherein the plant-derived powder material is dispersed on a conveyor belt, and the radiation emitter of the plant material moisture detector is positioned on one side of the conveyor belt and the radiation receiver of the plant material moisture detector is positioned on the opposite side of the conveyor belt such that the radiation of the plant material moisture detector passes through the plant-derived powder material. Example E5: The method according to any one of Examples E1 to E4, wherein the plant-derived powder material contains tobacco powder, preferably the plant-derived powder material is tobacco powder, and the material sheet is a sheet of an aerosol-forming substrate. Example E6: The method according to any one of Examples E1 to E5, wherein the plant-derived powder material is adjusted to a particle size of 20 μm to 200 μm, preferably 50 μm to 100 μm, before forming the slurry. Example E7: The method according to any one of Examples E1 to E6, wherein the particle size of the plant-derived powder material is determined, preferably before determining the moisture content of the plant-derived material. Example E8: The method according to any one of Examples E1 to E7, wherein a water flow controller is employed, and the flow controller controls the amount of water added for slurry formation based on the determined moisture content of the plant-derived powder material. Example E9: The method according to Example E8, wherein an open-loop control system is employed, and the open-loop control system adjusts the pump speed of the flow controller based on the determined moisture content of the plant-derived powder material. Example E10: The method according to any one of Examples E1 to E9, wherein the cellulose-based sheet former contains cellulose fibers, preferably water / cellulose fiber pulp is prepared and mixed with the plant-derived powder material, and more preferably the water / cellulose fiber pulp contains cellulose fibers having an average length of 0.2 millimeters to 4 millimeters, more preferably 1 millimeter to about 3 millimeters. Example E11: The method according to any one of Examples E1 to E10, wherein the targeted water content range of the slurry is 55 weight percent to 85 weight percent water, preferably the targeted water content range of the slurry is 60 weight percent to 80 weight percent water, based on the total weight of the slurry. Example E12: A method according to any one of Examples E1 - E11, wherein the slurry is dried to form a plant-derived sheet, the plant-derived sheet has a moisture content of 7% to 15% of the dry weight of the sheet, preferably the plant-derived sheet has a moisture content of 8% to 12% of the dry weight of the sheet. Example E13: A method according to any one of Examples E1 - E12, wherein one or both of a thickening agent and an aerosol former are added to form the slurry, preferably the thickening agent contains guar, and the aerosol former contains one or more of triethylene glycol, 1,3 - butanediol, and glycerin. Example E14: A method according to any one of Examples E1 - E13, wherein the slurry has a targeted moisture content range, and the sum of the determined moisture content of the plant-derived powder material and the amount of water added for slurry formation results in a moisture content of the slurry that falls within the targeted moisture content range. Example E15: A method according to Example E14, wherein the moisture content of the cellulose-based sheet former is determined, and the sum of the determined moisture content of the plant-derived powder material, the amount of water added for slurry formation, and the moisture content of the cellulose-based sheet former results in a moisture content of the slurry that falls within the targeted moisture content range. Example E16: A method according to Example E15, further dependent on Example E13, wherein the moisture content of one or both of the thickening agent and the aerosol former is determined, and the sum of the determined moisture content of the plant-derived powder material, the amount of water added for slurry formation, the moisture content of the cellulose-based sheet former, and one or both of the thickening agent and the aerosol former results in a moisture content of the slurry that falls within the targeted moisture content range. Example E17: Equipment configured to produce a sheet of plant-derived material, - A mixing tank containing a stirrer, the mixing tank being configured to mix a plant-derived powder material and a cellulose-based sheet former to form a slurry, - A plant material moisture detector configured to determine the moisture content of the plant-derived powder material, - A water flow controller configured to provide water to a mixing tank, further configured to provide a certain amount of water to the mixing tank for slurry formation, wherein the amount of water is calculated based on the determined moisture content of the plant-derived powder material, the water flow controller; - A drying device for drying the slurry to form a plant-derived sheet, and a facility comprising the same. Example E18: The facility according to Example E17, comprising an open-loop control system, wherein the open-loop control system is configured to adjust the pump speed of the flow controller based on the determined moisture content of the plant-derived powder material. Example E19: The slurry has a target moisture content range assigned to it, and the open-loop control system is configured to provide such a certain amount of water to the mixing tank, so that the sum of the determined moisture content of the plant-derived powder material and the amount of water added for slurry formation results in a moisture content of the slurry that falls within the target moisture content range. The facility according to Example E18.
[0071] The features described with respect to one embodiment may be equally applicable to other embodiments of the present invention.
[0072] Although for illustrative purposes only, the present invention will be further described with reference to the following accompanying drawings.
Brief Description of the Drawings
[0073]
Figure 1
Figure 2
Modes for Carrying Out the Invention
[0074] Hereinafter, elements having the same functionality are denoted by the same reference numerals throughout all the figures.
[0075] FIG. 1 shows a schematic view of one embodiment of a facility 30 for manufacturing a plant-derived material sheet. Preferably, this facility 30 is configured to manufacture a tobacco-derived material sheet for forming an aerosol-forming substrate.
[0076] The apparatus 30 includes a conveyor belt 14 for conveying the plant-derived powder material 10 to the plant-derived powder material hopper 15. There is a plant material moisture detector 12. This plant material moisture detector 12 is configured to determine the moisture content of the plant-derived powder material. The plant material moisture detector 12 is connected to a flow controller 26. This flow controller 26 can determine the amount of water added for slurry formation based on the determined moisture content of the plant-derived powder material. The flow controller 26 can control the water inlet 20 to control the overall amount of water added for slurry formation. This water inlet 20 is part of a first delivery line 20A for the water added for slurry formation and for the delivery of the cellulose-based sheet former. There is a second delivery line 22A controlled by a separate water inlet 22. This second delivery line 22A delivers a thickener, such as guar and an aerosol former, to the mixer 18 for slurry formation. The plant-derived powder material hopper 15 conveys the plant-derived powder material to the silo 16A via a first conveyor belt 17A for storage. The plant-derived powder material is then further conveyed to the mixer 16B by a second conveyor belt 17B, and the mixer 16B finally conveys the plant-derived powder material to the slurry mixer 18. The mixer 16B may receive the plant-derived powder material and a certain amount of water to produce a mixture of the plant-derived powder material and water. This mixture can then be added to the slurry mixer 18. In the slurry mixer 18, the plant-derived powder material is mixed with the amount of water determined by the flow controller, the cellulose-based sheet former, the thickener and the aerosol former for slurry formation. Such an apparatus enables the water flow rate of the water added for slurry formation to be adapted based on the calculated moisture content of the plant-derived material determined via the plant material moisture detector 12.
[0077] Figure 2 illustrates a schematic diagram of a plant material moisture detector 12 having a radiation emitter 12A and a radiation receiver 12B. The microwave radiation indicated by the dashed line is emitted by the radiation emitter 12A of the plant material moisture detector 12. This emitted microwave radiation passes through the plant-derived powder material 10 located on the conveyor belt 14 and is received by the radiation receiver 12B. This microwave radiation that has passed through the plant-derived powder material can be employed to calculate the moisture content of the plant-derived powder material. Moisture in the plant-derived powder material causes attenuation and phase shift of the microwave radiation passing through the material. The comparison between the microwave radiation received by the radiation receiver and the microwave radiation emitted by the radiation emitter enables the determination of the overall attenuation and phase shift of the microwave radiation because the microwave radiation interacts with both the plant-derived powder material and the moisture content of the material. The flow controller 26 includes a module 26A for the calculation of the moisture content and a module 26B for communication between the data processing unit and the plant material moisture detector 12. The communication module 26B can communicate with a modem 32 for communication. This modem 32 can further communicate with a data processing unit 34. This data processing unit is also configured to control equipment configured to manufacture plant-derived material sheets. There can be a conveyor belt compensation device 36 that can generate a compensation signal due to any incidental absorption of microwaves by the material of the conveyor belt. The compensation device may provide a compensation signal in the range of 4 milliamperes to 20 milliamperes. The arrow indicated by "1" shows the communication line for amplitude attenuation. The arrow indicated by "2" shows the communication line for phase shift. These two communication lines provide additional information about the amplitude attenuation and phase shift that are caused only by the plant-derived powder material and not by the moisture content of the material. This enables the module 26A for the calculation of the moisture content to correctly determine the amplitude attenuation and phase shift of the microwave radiation that are caused only by the moisture and not by the plant-derived material itself. This enables an accurate determination of the moisture content of the plant-derived powder material.
Claims
1. A method for manufacturing a plant-derived material sheet, comprising: - providing a plant-derived powder material and a cellulose-based sheet-forming agent; - determining the moisture content of the plant-derived material; - mixing the plant-derived powder material, the cellulose-based sheet-forming agent, and an amount of water to form a slurry; - drying the slurry to form the plant-derived sheet; and - wherein the amount of water added for slurry formation is calculated based on the determined moisture content of the plant-derived powder material.
2. The method according to claim 1, wherein the slurry has a targeted water content range assigned thereto, and the amount of water added for slurry formation is calculated such that the slurry reaches a water content within the targeted water content range assigned thereto.
3. A plant material moisture detector is employed to determine the moisture content of the plant-derived material, preferably the plant material moisture detector is one of a microwave detector or an infrared detector. The method according to any one of claims 1 to 2.
4. The method according to claim 3, wherein the plant-derived powder material is dispersed on a conveyor belt, and a radiation emitter of the plant material moisture detector is positioned on one side of the conveyor belt and a radiation receiver of the plant material moisture detector is positioned on the opposite side of the conveyor belt such that the radiation of the plant material moisture detector passes through the plant-derived powder material.
5. The method according to any one of claims 1 to 4, wherein the plant-derived powder material contains tobacco powder, preferably the plant-derived powder material is tobacco powder, and the material sheet is a sheet of an aerosol-forming substrate.
6. The method according to any one of claims 1 to 5, wherein the plant-derived powder material is adjusted to a particle size of 20 μm to 200 μm, preferably 50 μm to 100 μm, before forming the slurry.
7. The method according to any one of claims 1 to 6, wherein the particle size of the plant-derived powder material is determined, preferably before determining the moisture content of the plant-derived material.
8. A water flow controller is employed, and the flow controller controls the amount of water added for slurry formation based on the determined moisture content of the plant-derived powder material, according to any one of claims 1 to 7.
9. The cellulose-based sheet forming agent contains cellulose fibers, preferably water / cellulose fiber pulp is prepared and mixed with the plant-derived powder material, and more preferably the water / cellulose fiber pulp contains cellulose fibers having an average length of 0.2 millimeters to 4 millimeters, more preferably 1 millimeter to about 3 millimeters, according to any one of claims 1 to 8.
10. Based on the total weight of the slurry, the destined target moisture content range of the slurry is 55 weight percent to 85 weight percent water, and preferably the target moisture content range of the slurry is 60 weight percent to 80 weight percent water, according to any one of claims 1 to 9.
11. The slurry is dried to form the plant-derived sheet, and the plant-derived sheet has a moisture content of 7 percent to 15 percent of the dry weight of the sheet, and preferably the plant-derived sheet has a moisture content of 8 percent to 12 percent of the dry weight of the sheet, according to any one of claims 1 to 10.
12. The slurry has a destined target moisture content range, and the sum of the determined moisture content of the plant-derived powder material and the amount of water added for slurry formation results in a moisture content of the slurry that falls within the target moisture content range, according to any one of claims 1 to 11.
13. The moisture content of the cellulose-based sheet forming agent is determined, and the sum of the determined moisture content of the plant-derived powder material, the amount of water added for slurry formation, and the moisture content of the cellulose-based sheet forming agent results in a moisture content of the slurry that falls within the target moisture content range, according to the method of claim 12.
14. Equipment configured to manufacture a sheet of plant-derived material, - A mixing tank including a stirrer, the mixing tank being configured to mix a plant-derived powder material and a cellulose-based sheet forming agent to form a slurry, - A plant material moisture detector configured to determine the moisture content of the plant-derived powder material; - A water flow controller configured to provide water to the mixing tank, further configured to provide an amount of water to the mixing tank for slurry formation, the amount of water being calculated based on the determined moisture content of the plant-derived powder material, the water flow controller; - A drying device for drying the slurry to form a plant-derived sheet, the facility comprising.
15. The facility according to claim 14, comprising an open-loop control system, the open-loop control system being configured to adjust the pump speed of the flow controller based on the determined moisture content of the plant-derived powder material.