Tobacco Processing

Abstract

The present invention provides a method for producing dry ice-expanded tobacco and treated dry ice-expanded tobacco obtainable by this method. The present invention also provides a combustion aerosol delivery system, or an article or component therefor, comprising the treated dry ice-expanded tobacco.

Description

[Technical Field]

[0001] The present invention relates to a method, particularly a method, for treating dry ice expanded tobacco (DIET). [Background technology]

[0002] After harvesting, the tobacco material can be dried to prepare the leaves for consumption. The tobacco material can be further processed, for example, by aging or fermentation, to enhance the organoleptic properties of the tobacco. However, these processes can be tedious, and the quality of the resulting tobacco material can be variable. Processing to enhance or add flavor and aroma to the tobacco material at later stages of tobacco processing often involves adding one or more additives to the tobacco and can require additional processing steps and equipment, which can be costly and time-consuming. Summary of the Invention

[0003] According to a first aspect of the present invention, there is provided a method of treating dry ice expanded tobacco (DIET) encapsulated within a moisture-retaining material, comprising the step of exposing the tobacco to an ambient processing temperature above 45°C, wherein the tobacco has a mass of between 60 and 160 kg / m at the start of the method. 3 and a moisture content of about 10% to 23% before and during processing. This method can be used to produce tobacco with desirable organoleptic properties.

[0004] The expanded DIET may optionally be suitable for use in a combustion aerosol delivery system. Thus, according to a second aspect of the present invention, there is provided a method of producing a DIET for use in a combustion aerosol delivery system, comprising the step of exposing a DIET encapsulated in a moisture-retaining material to an ambient processing temperature of above 45°C, wherein the tobacco is heated to a temperature of between 60 and 160 kg / m at the start of the method. 3 and a moisture content of about 10% to 23% before and during processing. This method can be used to produce tobacco with desirable organoleptic properties.

[0005] The features of the aspects and embodiments described herein are applicable to both the first and second aspects of the invention.

[0006] The method of the first or second aspect may include the step of encapsulating or immobilizing the tobacco in a moisture-retaining material prior to exposing the tobacco to the specified conditions.

[0007] According to a third aspect, there is provided treated dry ice expanded tobacco obtainable by the method of the first or second aspect.

[0008] A fourth aspect provides treated dry ice expanded tobacco produced according to (or obtained by) the method of the first or second aspect.

[0009] A fifth aspect provides a component for use in a combustion aerosol delivery system, the component comprising the treated dry ice expanded tobacco material of the third or fourth aspect.

[0010] A sixth aspect provides an article for use in a combustion-based aerosol delivery system, the article comprising a component of the fifth aspect.

[0011] A further aspect provides an aerosol delivery system comprising the treated dry ice expanded tobacco of the third or fourth aspect, a component of the fifth aspect, or an article of the sixth aspect. The methods described herein may also further comprise incorporating the treated dry ice expanded tobacco material into a combustion aerosol delivery system, or a component or article therefor.

[0012] The methods described herein may further include incorporating the treated dry ice expanded tobacco material into a blend. The blend may be suitable for use in a combustion aerosol delivery system, or a component or article therefor. Suitable amounts of treated dry ice expanded tobacco material in the blend are provided below.

[0013] A further aspect provides the use of the processed dry ice expanded tobacco material of the third or fourth aspect to manufacture a component for use in a combustion aerosol delivery system.

[0014] The treated DIET may be used to produce a tobacco extract. A further aspect provides a tobacco extract produced from the DIET of the third or fourth aspect.

[0015] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0016] [Figure 1] FIG. 1 is a process flow diagram for producing dry ice expanded tobacco. [Figure 2] Cross-sections of tobacco leaves before (top) and after (bottom) dry ice expansion. The scale bar in each image (center, bottom) corresponds to a distance of 100 microns. [Figure 3] FIG. 1 is a process flow diagram for producing expanded stem tobacco. [Figure 4] This is a photo of the processed DIET passing through the doffer set. DETAILED DESCRIPTION OF THE INVENTION

[0017] Expanded tobacco material is tobacco material that has been subjected to an expansion process. Expansion involves increasing the volume of the tobacco material's cellular structure, which may result in an increase in the area and spacing between fibers present in the tobacco material. After being subjected to the expansion process, the tobacco material has a higher fill value but a lower density than the tobacco material before the expansion process. Expanded tobacco can be blended with other types of tobacco, for example, to provide smoking articles with a lower overall weight than conventional products. Reducing the overall weight can provide many benefits, such as reduced shipping costs. Furthermore, reducing the weight of the article can also have a positive impact on the environment, as less energy may be required to transport the article. Furthermore, consumers may prefer to carry and use lighter articles. Types of expanded tobacco include dry ice expanded tobacco and expanded stems. Expanded stems are formed by steam expansion of stem tobacco.

[0018] However, expanded tobacco materials can impair the organoleptic properties of tobacco blends containing them, and can limit the amount of expanded tobacco material that can be included in a blend while maintaining an acceptable taste profile.

[0019] The present invention relates to a method for treating dry ice expanded tobacco (DIET). The treated DIET may be for use in a combustion-based aerosol delivery system. This treatment advantageously alters the organoleptic properties of the DIET. However, the inventors have found that when the same treatment is performed on other types of expanded tobacco, these desirable changes in organoleptic properties are not observed. In particular, no significant changes in the taste profile between treated and untreated expanded stems (i.e., expanded stem tobacco before and after the treatment method described herein) were determined by expert smokers. In contrast, changes in the taste profile were observed between treated and untreated DIET (i.e., DIET before and after the treatment method described herein). That is, the inventors have surprisingly found that the method of the present invention is particularly suitable for improving the organoleptic properties of DIET, but not for improving the organoleptic properties of expanded stems.

[0020] The favorable changes in the organoleptic properties of DIET tobacco provided by the methods herein mean that treated tobacco can be added to tobacco blends (e.g., for use in smoking articles) in greater amounts than untreated DIET tobacco without compromising the organoleptic properties of the tobacco blend.

[0021] The inventors have also found that the high fill value of dry ice expanded tobacco is maintained during the process of the present invention, and the fill value of dry ice expanded tobacco may even increase during the process.

[0022] As used herein, the term "treated tobacco" refers to tobacco that has undergone the treatment methods described herein, and the term "untreated tobacco" refers to tobacco that has not undergone the treatment methods. The tobacco used in the methods of the present invention is dry ice expanded tobacco (DIET).

[0023] Tobacco goes through several steps before it can be consumed by a consumer. In the field, the following steps are usually carried out by farmers: sowing, transplanting, cultivating, harvesting, and curing.

[0024] Tobacco is generally dried after harvest to reduce the moisture content of the tobacco from typically about 80% to about 20% or less. Tobacco can be dried in several different ways, including air-curing, flame-curing, hot-air curing, and sun-curing. During the curing period, the tobacco undergoes certain chemical changes, changing color from green to yellow, orange, or brown. Temperature, relative humidity, and packing density are carefully controlled to prevent houseburn and spoilage, which are common problems encountered during curing.

[0025] In Green Leaf Threshing (GLT) plants, tobacco is sold by farmers and then typically undergoes the following steps: re-grading, green leaf blending, conditioning, stem removal by stemming or threshing (or not if whole leaf), drying, and filling.

[0026] Typically, after drying, the stems are removed from the blades. This can be done by deboning, where the midrib and partially the lamina veins are separated from the blades by mechanical deboning. An alternative method of removing the stems from the blades is by hand, using the so-called "hand stripping" process. Alternatively, the tobacco can be "butted," meaning that the thicker part of the stem is cut off, leaving the rest of the tobacco leaf intact.

[0027] In addition to curing, tobacco may be further processed to enhance its taste and aroma. Curing and fermentation are known techniques for enhancing tobacco taste and aroma. These processes can be applied to tobacco materials such as deboned lamina, hand-stripped lamina, butted lamina, and / or whole leaf tobacco.

[0028] Curing typically occurs after the tobacco has been dried, deboned (or butted or hand-stripped), and packed. Tobaccos that undergo aging include Oriental tobacco, flue-cured tobacco, and air-cured tobacco. During aging, tobacco may generally be stored for about 1 to 3 years at temperatures of about 20°C to about 40°C and relative humidity or under controlled warehouse conditions existing in the respective country of origin / aging.

[0029] Because mold forms in tobacco at higher moisture contents, it is important that the moisture content of the tobacco be maintained at a relatively low level during aging, e.g., a maximum of about 10-13%.

[0030] Fermentation is a process applied to certain tobaccos, including dark air-cured tobacco, cured oriental tobacco, and cigar tobacco, to give the tobacco a more uniform color and alter its aroma and taste. Fermentation is generally not applied to flue-cured and light air-cured tobaccos. Fermentation is also generally not applied to diet tobaccos.

[0031] Fermentation parameters, such as tobacco moisture content and ambient conditions, vary depending on the type of tobacco undergoing fermentation. Generally, the fermentation moisture is similar to the moisture content of the tobacco as received from the farmer (approximately 16-20%), or the tobacco is conditioned to a slightly higher moisture content. Care must be taken to avoid the development of various spoilage processes that occur when tobacco is fermented at too high a moisture content. The duration of the fermentation period can range from several weeks to several years.

[0032] Generally, fermentation involves the processing of large quantities of tobacco and is applied to the whole leaf, with the stems then being removed after processing. The tobacco can be placed in large piles, which are then rotated at intervals to move the peripheral tobacco toward the center of the pile. Alternatively, the tobacco can be placed in a chamber having a volume of several square meters. Processing such large quantities of tobacco can be cumbersome and / or time-consuming.

[0033] Importantly, fermentation relies on the activity of microorganisms to effect changes in the tobacco material, and fermentation conditions, including the temperature and moisture content of the tobacco, are selected to enhance microbial activity during fermentation. For example, temperature must be controlled during the fermentation process, typically within the range of 38-40°C. In most, if not all, tobacco fermentations rely on microorganisms already present in the tobacco material. However, appropriate microorganisms may be added to the tobacco material at the beginning of the fermentation process.

[0034] After the above treatments, the tobacco is typically transported to another location where it is further processed, for example, before being incorporated into a tobacco-containing product. If the tobacco is to be incorporated into a smoking article such as a cigarette, it is typically opened, conditioned, blended with other tobacco styles and / or types and / or varieties, cut, dried, blended with other tobacco materials, and delivered to a cigarette manufacturing unit.

[0035] Additionally or alternatively, tobacco may be treated with additives to improve or enhance the flavor and aroma of the tobacco. However, this requires additional processing steps and equipment, making the tobacco preparation process longer and often more expensive. Furthermore, it may be desirable to have tobacco material that has a taste and aroma that consumers enjoy, but to which no additives have been applied to achieve this. This would be the case, for example, for consumers who desire a natural tobacco product with a similarly pleasant flavor and / or taste. Additives are generally applied where the smoking article is manufactured, such as in a cigarette factory, although the point at which the additives are applied can vary.

[0036] In some embodiments, the methods of processing tobacco material described herein produce dry ice expanded tobacco material with desirable organoleptic properties without the addition of flavorings or aroma additives, within a period that may be shorter than more traditional techniques such as fermentation and aging. In some embodiments, the methods of the present invention do not involve fermentation, or are essentially free of fermentation. This may be evidenced by little or no microbial content of the tobacco material at the end of the method. Thus, in one embodiment, the microbial content of the tobacco material at the end of the method is lower than the microbial content of the tobacco material at the start of the method.

[0037] In some embodiments, the methods of processing dry ice-expanded tobacco material described herein produce tobacco with an enhanced flavor profile or enhanced organoleptic properties (compared to the flavor profile of dry ice-expanded tobacco that is untreated or processed using only conventional curing processes). This means that off-notes or irritants are reduced while maintaining the tobacco's taste characteristics as seen after conventional curing. As used herein, the terms "enhance" or "enhance" are used in the context of flavor or organoleptic properties to mean that there is an improvement or refinement of taste or taste quality as perceived by expert smokers. This may, but does not necessarily, include taste enhancement.

[0038] In some embodiments, the methods of processing dry ice expanded tobacco material described herein produce tobacco material with reduced at least one undesirable taste or flavor characteristic, such as reduced dryness and harsh off-notes.

[0039] In some embodiments, the methods described herein can be used to enhance the organoleptic properties of dry-ice-expanded tobacco starting materials that have poor organoleptic (e.g., taste) properties. It has been found that at least one effect of processing on dry-ice-expanded tobacco materials is the removal or reduction of organoleptic factors that negatively affect the overall organoleptic properties of the tobacco material. In some embodiments, the methods can also result in an increase in positive organoleptic properties.

[0040] In some embodiments, the method for treating dry ice expanded tobacco can be adjusted to produce a treated material with specific selected organoleptic properties, which may involve, for example, adjusting one or more of the parameters of the method.

[0041] In some embodiments, the methods of processing dry ice-expanded tobacco material described herein transform the flavor profile of the tobacco (compared to the flavor profile of dry ice-expanded tobacco that is untreated or processed using only conventional curing processes). This means that there is a significant change in the organoleptic properties of the tobacco after processing, resulting in a change in the taste characteristics of the tobacco compared to the taste characteristics of untreated DIET tobacco. As used herein, the terms "transform" or "transformation" are used in the context of flavor or organoleptic properties to mean that there is a change from one overall taste or sensory characteristic to another, as discerned by expert smokers. This may include an improvement and / or refinement of taste or taste quality.

[0042] In some embodiments, including those in which the organoleptic properties of the tobacco starting material are altered, processing has the effect of not only reducing or eliminating organoleptic factors having a negative effect, but also introducing or increasing organoleptic factors having a positive effect. For example, in some embodiments, the methods described herein result in an increase in products of the Maillard reaction, many of which are known to contribute to desirable organoleptic properties.

[0043] References herein to the organoleptic properties of a tobacco material may refer to the organoleptic properties of the tobacco material itself, for example, when used orally by a consumer. Additionally or alternatively, reference may be to the organoleptic properties of the smoke produced by burning the tobacco material or the vapor produced by heating the tobacco material. In some embodiments, the processed tobacco material provides a tobacco product comprising said tobacco material with desirable organoleptic properties when the tobacco product is used or consumed.

[0044] The tobacco material used in the present disclosure is dry ice expanded tobacco. As used herein, the term "tobacco material" includes any part of any member of the genus Nicotiana and any associated by-products, such as leaves or stems. Tobacco material for use in the present invention is preferably derived from the species Nicotiana tabacum.

[0045] Any type, style, and / or variety of dry ice expanded 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 will result in tobacco with different organoleptic characteristics.

[0046] In some embodiments, the tobacco material comprises lamina tobacco material. The tobacco may comprise between about 70% and 100% lamina material by weight. For example, the tobacco may comprise between about 80% and 100% lamina material by weight, such as between about 90% and about 99% lamina material by weight.

[0047] The tobacco material may comprise up to 50%, up to 60%, up to 70%, up to 80%, up to 90%, or up to 100% by weight of flank tobacco material. In some embodiments, the tobacco material comprises up to 100% by weight of flank tobacco material. In other words, the tobacco material may comprise substantially entirely or entirely flank tobacco material.

[0048] In certain embodiments, the tobacco material comprises, consists essentially of, or consists of leaf tobacco, such as leaf tobacco including leaf Virginia tobacco. In some cases, the leaf tobacco may be selected from Virginia tobacco or a blend of Virginia and burley tobacco. The weight ratio of Virginia to burley may be 1:10 to 10:1, e.g., 1:5 to 5:1, 1:2 to 2:1, 1:1.5 to 1.5:1, or 1.2:1 to 1:1.2.

[0049] Alternatively or additionally, the tobacco material may comprise at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, or at least 95% by weight of leaf tobacco material.

[0050] When the tobacco material includes a blade tobacco material, the blade may be in whole leaf form or in shredded form. Typically, the tobacco material (such as blade tobacco) is in shredded form. The use of shredded tobacco reduces the time required for liquid carbon dioxide to impregnate / permeate the tobacco during dry ice expansion.

[0051] In some embodiments, the diet tobacco material comprises stem tobacco material. The tobacco may comprise up to about 20% by weight of stem material, such as up to about 15% by weight of stem material. For example, the tobacco material may comprise 1-20% by weight of stem material and 80-99% by weight of lamina tobacco, such as 5-15% by weight of stem material and 85-95% by weight of lamina material.

[0052] Pre-prepared diets can be processed according to the methods of the present invention. For example, diets are commercially available. Alternatively, the method can involve dry ice expansion of tobacco material to provide a diet, followed by processing the diet as described herein.

[0053] Methods for forming DIETs are known in the art. For example, dry ice expansion involves infiltrating (or impregnating) tobacco with liquid carbon dioxide under pressure, e.g., by submerging and immersing the tobacco in liquid carbon dioxide. Excess liquid and / or gaseous carbon dioxide can be recovered for reuse, e.g., by draining the liquid. The method may include converting the liquid carbon dioxide in the tobacco to solid carbon dioxide (dry ice), e.g., by reducing the pressure. If the system is unpressurized, the carbon dioxide in the tobacco solidifies to dry ice. This phase change can occur at the triple point pressure of CO2 (60.4 psig and minus 69.83°F). The solid carbon dioxide is then subjected to conditions that cause it to vaporize (or sublimate to form gaseous carbon dioxide), thereby expanding the tobacco material. For example, the tobacco material containing the solid carbon dioxide can be rapidly heated as shown below. After warming, the dry ice sublimes to form gaseous carbon dioxide, thereby expanding the tobacco.

[0054] A suitable method for dry ice expansion may include impregnating the cellular structure of tobacco with liquid carbon dioxide. Typically, the tobacco impregnated is cut tobacco. Suitable conditions for this impregnation step may include contacting the tobacco material in an impregnation vessel with liquid carbon dioxide under pressure at a temperature of -40 to -10°C, e.g., -25 to -15°C, for approximately 1 to 10 minutes, e.g., 2 to 8 or 3 to 7 minutes. The pressure may be, for example, 435 psig (3000 kPa). Suitable cut widths are disclosed below in the description of FIG. 1. Immediately prior to impregnation, the tobacco material may have a moisture content of 10 to 40%, e.g., 15 to 35%, or 20 to 30%. After the impregnation step, the method then typically includes reducing the pressure in the impregnation vessel sufficiently to cause solidification of the liquid carbon dioxide within the cellular structure. For example, the pressure may be reduced to atmospheric pressure (1 atm). The method may then involve rapidly heating the tobacco to sublimate the solid carbon dioxide within the tobacco cells, thereby expanding the tobacco. This rapid heating may be accomplished by introducing the tobacco material containing the solid carbon dioxide into a gas stream having a temperature of 250-400°C, e.g., 300-360°C, or about 330°C. The method may then include hydrating the dry ice expanded tobacco to a desired initial moisture content for further processing by the method of the present invention.

[0055] FIG. 1 illustrates a suitable exemplary method for preparing dry ice-expanded tobacco. A bale of tobacco material is sliced, and then the bale is conditioned using water and steam. The tobacco material can be any of the tobacco materials described herein. Leaf tobacco, particularly leaf Virginia tobacco, is particularly preferred. One reason for this is that leaf Virginia tobacco exhibits desirable organoleptic properties and has relatively low levels of compounds considered undesirable compared to other tobacco varieties. Another advantage of using Virginia tobacco is that it tends to expand easily during the expansion process. In some embodiments, stem tobacco can be used in addition to leaf tobacco. After conditioning, the conditioned tobacco material is blended with other conditioned tobacco materials or mixed before feeding to a cutter. Preferably, the cutter cuts the tobacco material at 25 to 28 cuts per inch (CPI). While other cutting widths can be used, a cutting width of 25 CPI is particularly preferred. Cutting the tobacco material increases its surface area, thus reducing the time it takes to be impregnated with liquid during the impregnation step. These cut widths may also increase the fill value of the final material.

[0056] After wetting the cut material and blending the wet-cut material, the material has a moisture content of approximately 26%. The material is then fed into an impregnation vessel, which is then charged with carbon dioxide under pressure at a temperature of -20°C for approximately 6 minutes. These conditions ensure that the carbon dioxide remains in liquid form and has sufficient time to penetrate and be absorbed into the tobacco material. Following this, the impregnated tobacco material is fed into a sublimator, where the pressure is reduced to solidify the liquid carbon dioxide, and the impregnated tobacco material is then heated in a gas stream at a temperature of 330°C. This heating results in the rapid volatilization of the moisture and carbon dioxide in the tobacco material, causing the tobacco material to expand.

[0057] Other gas temperatures may be used. For example, the gas temperature may be about 250°C to about 400°C or higher. The maximum temperature is preferably below the combustion temperature of the tobacco material. Higher temperatures may improve the expansion rate and therefore the process efficiency. The fill value of the tobacco material may also be controlled by varying the temperature. Increasing the temperature may force more moisture out of the material, thus increasing the fill value of the final material. Conversely, using a lower temperature may decrease the fill value of the final material.

[0058] The high gas temperature can be achieved by any suitable means (e.g., by heating the air using a hot plate or burner). At the end of sublimation, the tobacco material is relatively dry, with a moisture content of about 6%. The moisture content is increased to about 12% to 14% (the target is often 13.6%) by hydrating the tobacco material in a sorting cylinder to produce the final expanded tobacco material. The expanded material is heated to a temperature of at least about 6 cm. 3 / g.

[0059] When referring to "moisture," it is important to understand that widely varying and contradictory definitions and terminology are used. While "moisture" or "moisture content" is commonly used to refer to the moisture content of a material, for certain industries, such as the tobacco industry, it is necessary to distinguish between "moisture" as water content and "moisture" as oven volatiles. Moisture content is defined as the percentage of water contained in the total mass of solid material. Volatiles are defined as the percentage of volatile components contained in the total mass of solid material. Volatiles include water and all other volatile compounds. Oven dry mass is the mass remaining after volatiles have been driven off by heating. Oven dry mass is expressed as a percentage of the total mass. Oven volatiles (OV) is the mass of volatiles driven off.

[0060] The moisture content (oven volatiles) may be measured as the mass loss when the sample is dried in a forced draft oven for 3 hours ± 0.5 minutes at a temperature adjusted to 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.

[0061] Unless otherwise stated, references to moisture content herein are references to oven volatiles (OV).

[0062] Figure 2 shows cross-sections of tobacco leaves before (top) and after (bottom) dry ice expansion. The scale bars in each image (center, bottom) correspond to a distance of 100 microns. The expansion of the tobacco material during the dry ice expansion process can be seen by comparing these images.

[0063] Another known type of expanded tobacco for dietary use is expanded stems (which may also be called expanded stems or steam-treated stems (STS)). The process of forming expanded stems typically involves treating the stems with steam, which causes the material to expand and increase its fill value.

[0064] FIG. 3 illustrates one such method for expanding tobacco stems. Tobacco is loaded into a feeder. The tobacco stems may be from any of the tobacco varieties described herein. After the addition of water, the moisture content of the stems is about 34%. The mixture is then blended and / or thoroughly mixed with another batch of stems, at which point the stems have a moisture content of about 30% to about 40%, e.g., about 36%. The material is then cut to ensure consistent dimensions of the stem sections. This cutting can help further increase the fill value of the material. Water is then applied to the cut stems to increase their moisture content to about 35% to about 45%. The relatively high moisture level achieved in this step helps increase the expansion of the stems during the subsequent expansion step. The material is then subjected to steam treatment (e.g., using steam or superheated steam) at temperatures above 100°C, which results in the expansion of the stems and an increase in their fill value. The steam can be applied at a rate of at least 200 kg / hour, for example, greater than 300 kg / hour or greater than 350 kg / hour, for example, from about 375 kg / hour to about 500 kg / hour. Higher application rates can also be used. The throughput rate can be increased by using a higher steam application rate. After removing dust using a dust collector, the expanded stems can be stored.

[0065] As noted in the Summary of the Invention, the moisture content of the DIET before and during processing is from about 10% to about 23%. As used herein, the term "moisture content" refers to the percentage of oven volatiles present in the DIET material.

[0066] In some embodiments, the moisture content of the diet before and during processing is about 10% to 15.5%, and sometimes about 10.5% to 15% or about 11% to 14%. The moisture content of the diet can be about 10%, about 11%, about 12%, about 13%, about 14%, about 15%, about 16%, about 17%, about 18%, about 19%, about 20%, about 21%, about 22%, or about 23%.

[0067] In some embodiments, for example, when the moisture content of the DIET is between about 10% and 20%, and in some cases between about 10% and 18%, it is not necessary to re-dry the tobacco after the treatment process.

[0068] The DIET material is encapsulated, e.g., immobilized, within a moisture-retaining material to limit moisture loss and maintain a desired moisture level during processing. The method may further include encapsulating or immobilizing the DIET material within a moisture-retaining material prior to treating the tobacco according to the method of the present invention.

[0069] The dietary supplement may be completely sealed within the moisture-retaining material. Alternatively, the dietary supplement may not be completely sealed within the moisture-retaining material. In some embodiments, the moisture-retaining material is wrapped around the dietary supplement. In other embodiments, the moisture-retaining material is wrapped around a storage container containing the dietary supplement. In some embodiments, the dietary supplement is placed within a moisture-retaining container. Thus, the method of the present invention may be performed on a dietary supplement in which the moisture-retaining material is wrapped around the dietary supplement or in which the moisture-retaining material is wrapped around a storage container containing the dietary supplement. Additionally or alternatively, the method of the present invention may be performed on a dietary supplement placed within a moisture-retaining container.

[0070] The moisture-retaining material can be any material that is sufficiently impermeable to moisture to retain a desired amount of moisture during the treatment process. The amount of moisture retained in the DIET material can be at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 91%, at least 92%, at least 93%, at least 94%, at least 95%, at least 96%, at least 97%, at least 98%, at least 99%, at least 99.5%, or 100% of the moisture present in the DIET material prior to treatment. In some embodiments, between 99% and 100% of the moisture content of the DIET material is retained during the process.

[0071] It is desirable for the moisture-retaining material to be resistant to degradation during the tobacco treatment process. For example, it is desirable for the moisture-retaining material to withstand the temperatures of the treatment process without breaking down and becoming permeable to moisture or releasing compounds that may be taken up by the tobacco material. Thus, when selecting a moisture-retaining material, the temperatures that the DIET material will reach during the process may be taken into consideration.

[0072] The moisture-retaining material may include a flexible material. This flexible material may be wrapped around the diet material and / or formed into a pouch into which the diet is placed. In some embodiments, the moisture-retaining material includes a plastic material. In some embodiments, the moisture-retaining material includes a flexible polymeric material, optionally a polymer or plastic film. In some embodiments, the moisture-retaining material includes polyethylene. In some embodiments, the moisture-retaining material includes polyester, nylon, and / or polypropylene. In some embodiments, the moisture-retaining material is Polyliner®. Polyliner® is available from several suppliers, including Plastrela Flexible Packaging, located in Brazil.

[0073] Alternatively or additionally, the moisture-retaining material may comprise a rigid material, such as metal, formed into a vessel or container. In these embodiments, the separate storage vessel described below may not be required.

[0074] In embodiments where the DIET material reaches temperatures of about 100° C. or greater, the moisture-retaining material may be pressure resistant.

[0075] In some embodiments, the method may include resting the tobacco material while encapsulated within the moisture-retaining material for a rest period prior to exposure to ambient processing temperatures. The rest period may be at least 15 days, such as at least 30 days. For example, the rest period may be 15 to 75 days, such as 20 to 60 days or 30 to 45 days.

[0076] At the beginning of the process, the DIET material is fed at a rate of 60-160 kg / m 3 In some embodiments, the DIET material has a packing density of 70 to 140 kg / m at the start of processing. 3 , 90~135kg / m 3 , 100-130kg / m 3 or 105 to 125 kg / m 3 The process / treatment begins upon exposure of the DIET to ambient processing temperatures as defined herein. That is, the DIET has a packing density of 60 to 160 kg / m when the DIET is exposed to ambient processing temperatures. 3 , e.g. 70-140 kg / m 3 , 90~135kg / m 3 , 100-130kg / m 3 or 105 to 125 kg / m 3 has a packing density of

[0077] Packing density herein is calculated by dividing the weight of the DIET by the volume occupied by the DIET. Packing density herein should be calculated based on the total weight of the tobacco material, including any water / moisture in the tobacco material.

[0078] If the volume of the storage container, the volume enclosed by the moisture-retaining material, and the volume occupied by the DIET are substantially the same or exactly the same (e.g., if the storage container is substantially completely or entirely filled with the DIET material and sealed, wrapped, or secured within the moisture-retaining material), the packing density can be calculated by dividing the weight of the tobacco placed in the storage container by the volume of the storage container.

[0079] The volume of the storage container and / or the volume enclosed by the moisture-retaining material (which may be substantially the same) may be selected to achieve a desired packing density for the desired amount of tobacco to be processed, while at the same time allowing the processing of the tobacco to occur at an appropriate rate.

[0080] If the DIET does not occupy the entire volume of the moisture-retaining material, the volume occupied by the DIET can be calculated by subtracting the volume of any empty space (e.g., the void space within the moisture-retaining material and optionally above the tobacco material after it has been placed in a storage container) from the total volume enclosed by the moisture-retaining material.

[0081] The packing density of the DIET material during and / or after processing can be similar or substantially similar to the packing density of the DIET material at the start of the process. In some cases, the packing density of the DIET material increases during and / or after processing because the volume occupied by the DIET material decreases during processing.

[0082] The dietary fiber material may be encapsulated or secured within the moisture-retaining material before being placed in the storage container. Alternatively, the dietary fiber material may be placed in the storage container and then encapsulated or secured within the moisture-retaining material, such as by wrapping the moisture-retaining material around the storage container. Placing the dietary fiber in the container allows for easy handling of the tobacco.

[0083] Alternatively or additionally, the container may be oriented horizontally, which may be particularly beneficial when the diet material includes tobacco lamina that are in a horizontal position when placed in the container, as placing the container horizontally achieves a more uniform packing density.

[0084] In some embodiments, the container is about 0.2 m 3 ~about 1.0m 3 , in some cases about 0.4 m 3 ~approx. 0.8m 3 In some embodiments, the container has a volume of about 0.7 m 3 It has a volume of

[0085] In some embodiments, the volume occupied by the DIET material at the start of the process is about 0.2 m 3 ~about 1.0m 3 , in some cases about 0.4 m 3 ~approx. 0.8m 3In some embodiments, the volume occupied by the DIET material at the start of the process is about 0.7 m 3 is.

[0086] In some embodiments, the storage container is a cigarette case known as a C-48 box, which is generally made of cardboard and has dimensions of approximately 115 x 70 x 75 cm.

[0087] The DIET may be placed in a tobacco processing area. As used herein, the term "tobacco processing area" refers to an area, which may be a room or chamber, where the treatment process takes place. Ambient process conditions, i.e., the conditions in the tobacco processing area, may be controlled during the process. This may be achieved by placing the DIET material, encapsulated or immobilized in a moisture-retaining material, in a controlled environment, such as a chamber. The DIET material may be placed on one or more racks within the chamber to allow optimal ventilation to maintain constant ambient process conditions around the tobacco. The racks may have one or more shelves with bars having gaps and / or other openings between the bars to help maintain constant ambient process conditions around the tobacco.

[0088] The ambient processing humidity can be maintained at a level that avoids significant moisture loss from the DIET material. As used herein, the term "ambient processing humidity" refers to the humidity of the tobacco processing area. As used herein, the term "ambient relative processing humidity" refers to the relative humidity of the tobacco processing area.

[0089] In some embodiments, the ambient relative processing humidity is about 65%. The ambient relative processing humidity can be at least 40%, at least 45%, at least 50%, at least 55%, at least 60%, at least 65%, or at least 70%.

[0090] The ambient processing temperature is at least about 45° C. In some embodiments, the ambient processing temperature is at least about 50° C. In some embodiments, the ambient processing temperature may be maintained above 55° C., and in some cases at about 60° C. As used herein, the term "ambient processing temperature" refers to the temperature of the tobacco processing zone.

[0091] In some embodiments, the ambient processing temperature is at least 46°C, at least 47°C, at least 48°C, at least 49°C, at least 50°C, at least 51°C, at least 52°C, at least 53°C, at least 54°C, at least 55°C, at least 56°C, at least 57°C, at least 58°C, at least 59°C, at least 60°C, at least 61°C, at least 62°C, at least 63°C, at least 64°C, at least 65°C, at least 66°C, at least 67°C, at least 68°C, at least 69°C, or at least 70°C. In some embodiments, the ambient processing temperature is at most 60°C, at most 70°C, at most 75°C, at most 80°C, at most 85°C, at most 90°C, at most 95°C, at most 100°C, at most 105°C, at most 110°C, at most 115°C, or at most 120°C.

[0092] In embodiments where the ambient processing temperature is about 45°C, the ambient processing humidity is about 30-70 g water / m 3 In embodiments where the ambient processing temperature is about 55°C, the ambient processing humidity may be about 40-80 g water / m 3 In embodiments where the ambient processing temperature is about 60°C, the ambient processing humidity may be about 50-110 g water / m 3 In embodiments where the ambient processing temperature is about 70°C, the ambient processing humidity may be about 50-160 g water / m 3 In embodiments where the ambient processing temperature is about 80°C, the ambient processing humidity may be about 50-230 g water / m 3 In embodiments where the ambient processing temperature is about 90°C, the ambient processing humidity may be about 50 to 340 g water / m 3 In embodiments where the ambient processing temperature is about 100°C or higher, the ambient processing humidity may be about 50-500 g water / m 3 It could be.

[0093] In some embodiments, the ambient processing temperature is 60° C. and the ambient relative processing humidity is 60%.

[0094] During processing, the temperature of the DIET material reaches an ambient processing temperature. The DIET material may reach the ambient processing temperature within a short period of time. For example, the DIET material may reach the ambient processing temperature within 4 to 10 days, possibly within 5 to 9 days, within 7 to 9 days, and / or within 4 to 7 days.

[0095] To achieve this, the amount of DIET processed can be optimized so that heat is transferred to the center of the tobacco material quickly enough. The rate at which the temperature of the DIET material increases and reaches the ambient processing temperature depends on several factors, including the ambient processing temperature, the density of the DIET, and the total amount of DIET processed.

[0096] In some embodiments, the DIET material reaches a temperature of greater than 55°C and / or at least 60°C within about 9 days. In some embodiments, the DIET material reaches a temperature of greater than 55°C and / or at least 60°C within about 7 days. In some embodiments, the DIET material reaches a temperature of greater than 55°C and / or at least 60°C within about 5 days. In such embodiments, the ambient processing temperature may be 60°C.

[0097] In some embodiments, the temperature to which the DIET material is raised is at least about 55° C. or at least about 60° C. Additionally or alternatively, the temperature to which the DIET material is raised can be up to about 80° C., up to about 85° C., up to about 90° C., up to about 95° C., or up to about 100° C.

[0098] In some embodiments, the beneficial effects of processing according to the present invention may be achieved within shorter processing periods by using higher ambient processing temperatures.

[0099] The temperature of the DIET material may increase during the treatment process to reach a second temperature that is higher than the ambient processing temperature, which may be achieved with the assistance of an exothermic reaction that occurs during the treatment process.

[0100] In some embodiments, the DIET material reaches a second temperature that is greater than the ambient processing temperature. In some embodiments, the second temperature is at least 1° C. greater than the ambient processing temperature, at least 2° C., at least 3° C., at least 4° C., at least 5° C., at least 7° C., at least 10° C., at least 12° C., at least 15° C., at least 17° C., or at least 20° C. greater than the ambient processing temperature. In some embodiments, the DIET material reaches the second temperature that is greater than the ambient processing temperature within about 7-13 days, and / or reaches the second temperature within about 13 days, or within about 11 days. In some embodiments, the DIET material reaches the second temperature that is at least 5° C. greater than the ambient processing temperature within about 11-13 days.

[0101] The temperature of the DIET material may reach up to 60°C, up to 65°C, up to 70°C, up to 75°C, up to 80°C, up to 85°C, up to 90°C, up to 95°C, up to 100°C, up to 105°C, up to 110°C, up to 115°C, up to 120°C, up to 125°C, up to 130°C, up to 135°C, up to 140°C, up to 145°C, or up to 150°C during the treatment process.

[0102] Alternatively or additionally, the temperature of the DIET material may reach at least 60° C., at least 65° C., at least 70° C., at least 75° C., at least 80° C., at least 85° C., at least 90° C., at least 95° C., at least 100° C., at least 105° C., at least 110° C., at least 115° C., at least 120° C., at least 125° C., at least 130° C., at least 135° C., at least 140° C., at least 145° C., or at least 150° C. during the treatment process. In practice, the upper temperature limit may be limited by the heat resistance of the moisture-retaining material.

[0103] In some embodiments, the temperature of the DIET material can reach about 55°C to about 90°C, about 55°C to about 80°C, or 60°C to about 70°C.

[0104] The DIET can be encapsulated or immobilized within a moisture-retaining material and exposed to ambient processing temperatures for a period long enough for the DIET to develop desirable organoleptic properties and short enough so as not to cause undesirable delays in the tobacco supply chain.

[0105] The DIET material is encapsulated or immobilized within a moisture-retaining material for a period of time at an ambient processing temperature and humidity suitable to raise the temperature of the tobacco above a threshold temperature, where the moisture content of the tobacco is between about 10% and 23%. In some embodiments, the threshold temperature is 55°C, 60°C, or 65°C.

[0106] In some embodiments, the DIET material is exposed to an ambient processing temperature above 45°C (or any of the ambient processing temperatures disclosed herein) for about 5 to 65 days, e.g., 10 to 50 days, 20 to 45 days, 30 to 40 days, or 35 to 40 days.

[0107] In other words, the treatment period (excluding the period during which the DIET material is encapsulated or immobilized within the moisture-retaining material prior to exposure to ambient processing temperatures) can be about 5 to 65 days, e.g., 10 to 50 days, 20 to 45 days, 30 to 40 days, or 35 to 40 days. For example, if the DIET is leaf Virginia tobacco, the treatment period can be 35 to 45 days. For example, if the DIET tobacco is a blend of leaf Virginia and leaf Burley tobaccos, the treatment period can be 30 to 40 days.

[0108] In other embodiments, the DIET material is exposed to an ambient processing temperature above 45° C. (or any of the ambient processing temperatures disclosed herein) for about 30 to 65 days, e.g., about 40 to 50 days, or about 43 to 48 days. In other words, the treatment period (excluding the period during which the DIET material is encapsulated or immobilized within the moisture-retaining material prior to exposure to the ambient processing temperature) can be about 30 to 65 days, e.g., about 40 to 50 days, or about 43 to 48 days. Increasing the treatment period can increase the amount of products of the Maillard reaction, thereby providing a stronger flavor profile for the treated DIET.

[0109] Embodiments in which the DIET material reaches a higher temperature may require a shorter process period than embodiments in which the DIET material reaches a lower temperature.

[0110] In other embodiments, the process involves treating the DIET material until the temperature of the DIET material reaches a target temperature, and then allowing the tobacco material to cool. This cooling may be accomplished by removing the DIET material from the processing zone, which is maintained at an elevated temperature. In some embodiments, the target temperature is 60°C, 61°C, 62°C, 63°C, 64°C, 65°C, 66°C, 67°C, 68°C, 69°C, or 70°C. In some embodiments, the target temperature is within the range of 62-67°C. The target temperature may vary depending on the type of tobacco.

[0111] After the treatment processes described herein, for example, after the tobacco has been exposed to ambient processing temperatures for any of the treatment periods described above, the DIET may be allowed to rest for a stabilization period, during which the DIET typically remains encapsulated or immobilized within the moisture-retaining material.

[0112] The stabilization period can be initiated by removing the DIET material from the processing zone maintained at an elevated temperature. For example, the DIET material can be transported to a different processing zone at a lower temperature, which can be about 30° C. or lower (e.g., about 18° C. to about 30° C., or about 20° C. to about 25° C., e.g., about 22° C.).

[0113] During the stabilization period, the temperature of the DIET is gradually reduced, typically to a temperature of about 30°C or below (e.g., about 18°C ​​to about 30°C, or about 20°C to about 25°C, e.g., about 22°C). After the treatment process, the moisture content of the periphery (or exterior or surface) of the body (e.g., bale) of the dry ice-expanded tobacco is typically higher than the moisture content of the center (or core) of the body of the dry ice-expanded tobacco. During the stabilization period, moisture from the peripheral dry ice-expanded tobacco can be reabsorbed by the central / core dry ice-expanded tobacco.

[0114] In other words, after the treatment process, moisture is typically not uniformly distributed throughout the batch of treated dry ice-expanded tobacco, with the dry ice-expanded tobacco on the periphery of the batch having a higher moisture content than the dry ice-expanded tobacco in the center (or core) of the batch. During the stabilization period, moisture can become uniformly distributed throughout the batch of treated tobacco material. This can help prevent microbial growth on the treated dry ice-expanded tobacco on the periphery of the batch, thereby reducing waste and improving the shelf life of the treated dry ice-expanded tobacco.

[0115] The moisture content of the DIET after the stabilization period can be from about 10% to about 18%, optionally from about 10% to about 15.5%, optionally from about 10.5% to about 15%, for example, from about 11% to about 14%.

[0116] The duration of the stabilization period can be at least 15 days, for example at least 30 days. For example, the stabilization period can be 15 to 75 days, for example, 20 to 60 days or 30 to 45 days. Typically, the stabilization period is about 40 days.

[0117] If the treatment process takes place within a storage container, such as a cardboard box as described above, the stabilization period may also allow the storage container to regain any rigidity lost during the treatment process, which may facilitate subsequent handling and transport of the treated dry ice expanded tobacco material.

[0118] The inventors have discovered that the treatment process described herein can result in the formation of hard agglomerates (also referred to as blocks or pads) of DIET tobacco. During the stabilization period, when the temperature of the treated DIET is gradually reduced, tobacco agglomerates may also form. Such agglomerates may need to be removed before the treated DIET can be used in products such as combustion aerosol delivery systems and / or components thereof. Furthermore, the inventors have determined that such tobacco agglomerates do not form when other forms of tobacco are subjected to DIET, such as when treating leaf tobacco that has not previously been dry ice expanded. Without wishing to be bound by theory, the inventors believe that tobacco agglomerates form due to the compressible or fluffy nature of dry ice-expanded tobacco. During the treatment process, when the temperature of the dry ice-expanded tobacco increases, the dry ice-expanded tobacco material on top of the moisture-retaining material may compress the dry ice-expanded tobacco material underneath, resulting in the formation of a compressed tobacco layer or tobacco agglomerates at the bottom of the body or batch of dry ice-expanded tobacco being treated.

[0119] In certain embodiments, after the treatment processes described herein, e.g., after exposing the tobacco to ambient processing temperatures for the treatment period described above, the method further includes one or more steps of breaking down agglomerates of tobacco material formed during the DIET treatment. For example, the method may further include applying one or more shear forces to the agglomerates of tobacco material and / or shredding the tobacco agglomerates.

[0120] The method may also be performed manually, for example, by using hands or hand tools (e.g., hammers, mallets, poles, etc.) to break up clumps of tobacco material formed during the DIET process. Alternatively, the method may be performed using a machine, for example, as part of a production line.

[0121] In certain embodiments, the method may further include passing the treated DIET through one or more rollers to break up tobacco clumps in the treated DIET. In certain embodiments, each of the one or more rollers includes a plurality of teeth, spikes, and / or protruding rods on its surface. In certain embodiments, the one or more rollers may be one or more doffers. The treated dry ice-expanded tobacco is typically spread on a conveying means, such as a conveyor belt, configured to transport the treated DIET toward the rollers. The conveying means and one or more rollers may be arranged such that, during use, the treated dry ice-expanded tobacco descends or drops through the one or more rollers, thereby breaking up one or more tobacco clumps. For example, multiple conveying means may be staggered so that there are one or more drop-offs between them, and one or more rollers may be positioned within the one or more drop-offs.

[0122] In some embodiments, the method may include multiple successive rolling steps. In certain embodiments, one or more rolling steps are continued until a target weight percent of tobacco agglomerates is reached, or a target weight percent of tobacco material with a particle size of 2.5 cm or less is reached. The target values ​​may be in the ranges set forth below, for example, a range of 15% by weight or less of tobacco agglomerates, or a DIET range of 85% by weight or more of particle size of 2.5 cm or less.

[0123] In some embodiments, the method may further include a first rolling step using one or more first rollers having a plurality of first teeth, first spikes, and / or first protruding rods on their surfaces, and a second rolling step using one or more second rollers having a plurality of second teeth, second spikes, and / or second protruding rods on their surfaces, wherein the spacing between the plurality of first teeth, first spikes, and / or first protruding rods is greater than the spacing between the plurality of second teeth, second spikes, and / or second protruding rods. The tobacco agglomerates are broken down into smaller agglomerates having a first particle size in the first rolling step. The smaller tobacco agglomerates provided by the first rolling step are then broken down into even smaller agglomerates having a second, smaller particle size in the second rolling step. In certain embodiments, the first rolling step is performed once, and the second rolling step is performed two or more times. The weight percent of tobacco clumps in the treated DIET can be further reduced by performing the second rolling step multiple times. In certain embodiments, the second rolling step is performed twice, i.e., the treated DIET is passed through one or more second rollers twice.

[0124] As used herein, weight percent of tobacco agglomerates refers to the mass percentage of the treated DIET material that does not pass through a 2.5 cm x 2.5 cm mesh relative to the total mass of the treated DIET material. In some embodiments, one or more steps of deagglomerating the tobacco material provides a DIET containing 15% or less by weight (i.e., 0-15%) tobacco agglomerates, optionally 10% or less by weight tobacco agglomerates, e.g., 5% or less by weight tobacco agglomerates, 2% or less by weight tobacco agglomerates, or 1% or less by weight tobacco agglomerates.

[0125] In other words, one or more steps of deagglomerating the tobacco material may provide a DIET in which 85% by weight or more (i.e., 85-100% by weight) of the DIET has a particle size of 2.5 cm or less, and in some cases 90% by weight or more, e.g., 95% by weight or more, 98% by weight or more, or 99% by weight or more of the DIET has a particle size of 2.5 cm or less. In this context, the weight percent of the treated DIET material having a particle size of 2.5 cm or less refers to the mass percentage of the treated DIET material that passes through a mesh with a pore size of 2.5 cm x 2.5 cm relative to the total mass of the treated DIET material.

[0126] Once one or more steps of deagglomerating the tobacco material have been performed (e.g., the treated tobacco has been spread and passed through one or more rollers), the treated DIET can be cooled more rapidly, and surprisingly, the stabilization period described above can be avoided without adversely affecting the fill value, moisture content, moisture distribution, and taste profile of the treated DIET. For example, the temperature of the DIET can be reduced to a temperature of about 30°C or below (e.g., about 18°C ​​to about 30°C, or about 20°C to about 25°C, e.g., about 22°C) over a period of 0.05 to 3 hours, optionally 0.1 to 2 hours, e.g., 0.15 to 1 hour, or 0.2 to 0.7 hours. By avoiding the stabilization period, the overall processing time of the DIET tobacco material can be significantly reduced.

[0127] A further aspect of the invention relates to a method comprising the step of breaking down tobacco clumps in a treated DIET material produced by the process described in the Summary of the Invention. The above embodiments apply mutatis mutandis to this aspect of the invention.

[0128] Filling value (also referred to herein as fill value) is a measure of the volume that a given mass of tobacco will occupy when a given pressure is applied at a given moisture content. That is, fill value is a measure of the ability of a material to occupy a specific volume at a given moisture content. In the present invention, filling value may be determined by Test Method A, disclosed in the Examples section below.

[0129] As shown above, the high fill value of the dry ice expanded tobacco is maintained during the process. The fill value of the dry ice expanded tobacco may even increase during the process. In some embodiments, the fill value of the treated DIET at a moisture content of 13.5% is at least 6 cm 3 / g, e.g., at least 6.5 cm 3 / g or at least 7cm 3 / g. In some embodiments, the loading value of the treatment diet at 13.5% moisture content is between 6 and 10 cm 3 / g, e.g., 6.5-9 cm 3 / g or 7-8cm 3 / g.

[0130] In some embodiments, the fill value of an untreated DIET at a moisture content of 13.5% is at least 6 cm 3 / g, e.g., at least 6.5 cm 3 / g or at least 7cm 3 In some embodiments, the loading value of untreated DIET at 13.5% moisture content is 6-10 cm 3 / g, e.g., 6.5-9 cm 3 / g or 7-8cm 3 / g.

[0131] It has been found that the change in at least one organoleptic property of the tobacco material is the result of a decrease in a negative property, for example, as a result of a decrease in a tobacco material component that has an unpleasant taste or irritating effect. In some embodiments, the organoleptic property is changed by an increase in a positive property, for example, as a result of an increase or introduction of a component that contributes positively to the organoleptic property, such as a component that has a pleasant flavor.

[0132] In some embodiments, the tobacco material is processed to have desirable organoleptic properties that can be produced in relatively large quantities in a reliable manner. In some embodiments, the process is a batch process.

[0133] After the DIET has been incubated for the desired length of time, the treated tobacco can be cooled while remaining within the moisture-retaining material.

[0134] The process parameters are sufficiently mild that the treated DIET material maintains some or all of its physical properties. For example, the DIET material remains sufficiently intact after treatment to allow handling and / or processing for incorporation into tobacco-containing products, such as smoking articles. This allows the treated DIET material to be handled by standard methods.

[0135] The treated DIET material may have a different color than the untreated DIET material, hi some embodiments, the DIET material is darker than the untreated tobacco material.

[0136] Importantly, the treated DIET material has organoleptic properties that are acceptable and / or desirable to consumers. Thus, tobacco materials with desirable organoleptic properties can be produced by DIET processing under a specific set of conditions without the need for the addition of one or more additional chemicals that may be harmful and / or expensive. Furthermore, the treated DIET does not need to undergo additional processing steps to remove the additional chemicals, which add extra cost and time to the tobacco processing process.

[0137] The organoleptic properties of the treated DIET material may be expressed when the tobacco material is encapsulated or immobilized within a moisture-retaining material, during which time components in the tobacco material undergo chemical changes and modifications to impart desirable organoleptic properties to the final product. In some embodiments, the treated tobacco material may have sweet, spicy, and / or dark notes. In some embodiments, the treated tobacco material may not have dry and / or bitter notes.

[0138] In some embodiments, the chemical composition of the treated dietary fiber material is significantly different from that of the untreated dietary fiber material. For example, as shown by the data presented in the Examples, in some embodiments, the majority of the sugars in the treated dietary fiber material are converted, and the concentrations of nicotine and total amino acids are reduced.

[0139] Without being bound by theory, it is believed that the changes in the levels of at least some of these compounds are at least partially due to the Maillard reaction occurring during processing. Caramelization reactions may also occur during processing, resulting in reduced levels of reducing and non-reducing sugars.

[0140] Additionally, in some embodiments, a significant reduction in the content of various amino acids may be observed.

[0141] Thus, the process may result in an increase in at least one product of the Maillard reaction in the treated DIET material, such as 2,6-deoxyfructosazine, 2,5-deoxyfructosazine, 5-acetyl-2,3-dihydro-1H-pyrrolidine, 2,3-dihydro-5-methyl-1H-pyrrolidine-7-carboxaldehyde, 1,2,3,4,5,6-hexahydro-5-(1-hydroxyethylidene)-7H-cyclopenta[b]pyridin-7-one, 1-(1-pyrrolidinyl)-2-butanone, 1-(2,3-dihydro-1 Examples of carotenoids include 2,3,4,5,6,7-hexahydro-cyclopenta[b]azepin-8(1H)-one, 5-(2-furanyl)-1,2,3,4,5,6-hexahydro-7H-cyclopenta[b]pyridin-7-one, 4-(2-furanylmethylene)-3,4-dihydro-2H-pyrrole, and 1,2,3,4,5,6-hexahydro-7H-cyclopenta[b]pyridin-7-one. Increased concentrations of carotenoids can also indicate that the Maillard reaction has occurred.

[0142] As shown in the examples, the treated DIET material may, in some embodiments, contain reduced levels of nicotine compared to untreated tobacco material. Nicotine is known to have a bitter taste, and therefore, reducing the level of this compound can have a positive effect on the taste and flavor of the treated tobacco material.

[0143] The production of a DIET material with desirable organoleptic properties advantageously eliminates the need to add additional substances to tobacco to provide or enhance those organoleptic properties, such substances including flavorings and / or aroma components.

[0144] As used herein, the terms "fragrance" and "flavoring" refer to materials that may be used, where local regulations permit, to create a desired taste or aroma in products intended for adult consumers. Fragrances or flavorings include extracts (e.g., licorice, hydrangea, magnolia leaf, chamomile, fenugreek, clove, menthol, peppermint, aniseed, cinnamon, herbs, wintergreen, cherry, berry, peach, apple, Drambuie, bourbon, Scotch, whiskey, spearmint, peppermint, lavender, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, honey essence, rose oil, vanilla, lemon oil, orange oil, cassia, caraway, cognac, jasmine, ylang ylang), and the like. The flavorings may include other additives such as spices, flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners. The flavorings may be imitation, synthetic, or natural ingredients, or blends thereof. The flavorings may be in any suitable form, such as an oil, liquid, or powder.

[0145] The treated DIET material may be incorporated into a combustion aerosol delivery system, which may also be referred to herein as a smoking article.

[0146] As used herein, the term "delivery system" is intended to encompass systems that deliver at least one substance to a user, and includes combustion-based aerosol delivery systems such as cigarettes, cigarillos, cigars, and pipe tobacco, or hand-rolled or hand-made cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes, or other smokable materials).

[0147] According to the present disclosure, a "combustion-based" aerosol delivery system is one in which the constituent aerosol-generating materials (or components thereof) of the aerosol delivery system are combusted or burned during use to facilitate delivery of at least one substance to a user.

[0148] In some embodiments, the combustion aerosol delivery system is selected from the group consisting of a cigarette, a cigarillo, and a cigar.

[0149] In some embodiments, the present disclosure relates to components for use in combustion aerosol delivery systems, such as aerosol modifier-releasing components such as filters, filter rods, filter segments, tobacco rods, spills, capsules, threads, or beads, or papers such as plug wrap, tipping paper, or cigarette paper.

[0150] The treated DIET material may be used in hand-rolled and / or pipe tobacco.

[0151] The treated DIET material may be blended with one or more tobacco materials before being incorporated into a smoking article, and may be used in hand-rolled or pipe tobacco.

[0152] In some embodiments, tobacco extracts can be made from DIET materials that have undergone processing as described herein. In some embodiments, the extract can be a liquid, such as an aqueous extract. In other embodiments, the extract can be produced by supercritical fluid extraction.

[0153] Accordingly, one aspect provides a method for producing a tobacco extract from DIET tobacco material that has been processed by the methods described herein.

[0154] In some embodiments, the extract may be used in a combustion aerosol delivery system, for example, the extract may be added to tobacco or another material for combustion in a smoking article.

[0155] As noted above, the favorable changes in the organoleptic properties of diet tobacco provided by the methods herein mean that treated tobacco can be added to a tobacco blend or combustion aerosol delivery system or component thereof (e.g., for use in a smoking article) in greater amounts than untreated diet tobacco, without impairing the organoleptic properties of the tobacco blend, combustion aerosol delivery system, or component thereof. Accordingly, the methods described herein may further include the step of incorporating treated tobacco into the blend.

[0156] In some embodiments, the tobacco blend may comprise treated tobacco in an amount of 1-60% by weight, such as 5-60% by weight, 10-55% by weight, 15-50% by weight, or 20-45% by weight, based on the total weight of the blend.

[0157] The blend may further include one or more other tobacco varieties, such as one or more Virginia tobaccos, one or more Burley tobaccos, one or more Oriental tobaccos, and combinations thereof. The treated dry ice expanded tobacco may contribute a dark taste characteristic, allowing the blend to provide sufficient dark taste notes with a low Burley tobacco content.

[0158] One or more aerosol-forming materials can be added to the diet provided by the methods described herein to provide a smokable material. The aerosol-forming material can include one or more components capable of forming an aerosol. In some embodiments, the aerosol-forming material can include one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0159] Smokable materials for use in combustion-based aerosol delivery systems typically contain less aerosol-forming material than aerosol-generating materials for use in non-combustion-based aerosol delivery systems. For example, smokable materials containing a DIET may contain a total amount of aerosol-forming material, calculated on a dry weight basis (DWB), of 0 to 20% by weight, e.g., 0.1 to 10% by weight (DWB), 0.25 to less than 10% by weight (DWB), e.g., 0.5 to 9% by weight (DWB), or 1 to 5% by weight (DWB). Smokable materials may contain less than 20% by weight (DWB), less than 10% by weight (DWB), less than 9% by weight (DWB), or less than 5% by weight (DWB). In these embodiments, the dry weight basis (DWB) refers to the entire smokable material excluding water, and may include components that are themselves liquid at room temperature and pressure, such as glycerol.

[0160] The DIET provided by the methods described herein, or a smokable material including the DIET (e.g., in combination with an aerosol former material), can be blended with additional ingredients to provide a blend, for example, as described above. The total amount of aerosol former material present in the blend can be 0 to less than 4% by weight (DWB), for example, 0.1 to 2% by weight. In these embodiments, the dry weight basis (DWB) refers to the entire blend excluding water, which may include ingredients that are themselves liquid at room temperature and pressure, such as glycerol.

[0161] To address various problems and advance the art, this entire disclosure illustrates various embodiments by way of example, in which the claimed invention may be practiced and provide improved tobacco processing methods. The advantages and features of this disclosure are merely a representative sample of embodiments and are not intended to be exhaustive and / or exclusive. They are presented solely to aid in understanding and teach the claimed features. The advantages, embodiments, examples, functions, features, structures, and / or other aspects of this disclosure should not be construed as limitations on the disclosure as defined by the claims or limitations on the equivalents of the claims, and it is understood that other embodiments may be utilized and modifications may be made without departing from the scope and / or spirit of the disclosure. Various embodiments may suitably comprise, consist of, or consist essentially of various combinations of the disclosed elements, components, features, parts, steps, means, etc. Additionally, this disclosure encompasses other inventions not currently claimed but which may be claimed in the future.

[0162] Example Test Method A In the following examples, the fill value of tobacco was measured according to the following method.

[0163] A 15g sample of tobacco material was placed in a 60mm diameter cylinder of a density meter, and then the tobacco material was compressed for 30 seconds with a 2.90±0.03kg piston. The height of the piston of the density meter and the moisture content of the sample were measured. The fill value of the sample was calculated according to the following formula:

[0164] The volume occupied by the tobacco material when compressed was determined using Equation 1.

number

[0165] The fill value was then determined using the measured volume and mass of the tobacco material according to Equation 2.

number

[0166] The loading values ​​were corrected to take into account their moisture content using Equation 3.

number

[0167] The moisture content (oven volatiles) is measured as the mass loss when the sample is dried in a forced draft oven for 3 hours ± 0.5 minutes at a temperature adjusted to 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.

[0168] Example 1 Diet cigarette manufacturing The leaf Virginia and leaf Burley tobaccos were conditioned, mixed, cut and dried.

[0169] The tobacco material was then formed into dry ice expanded tobacco. The Virginia and Burley cut tobaccos were moistened. For Sample R below, the Virginia and Burley tobaccos were then blended. The moistened and optionally blended tobacco material had a moisture content of approximately 26%. The tobacco material was then fed into an impregnation vessel, which was then filled with carbon dioxide under pressure at a temperature of -20°C for approximately 6 minutes. The impregnated tobacco material was then fed into a sublimator, which was then reduced in pressure to solidify the liquid carbon dioxide. The impregnated tobacco material was then heated in a gas stream at a temperature of 330°C, resulting in rapid volatilization of the moisture and carbon dioxide in the tobacco material.

[0170] Sample A below is dry ice expanded Virginia tobacco. Sample R below is a 1:1 w / w blend of dry ice expanded Virginia tobacco and dry ice expanded Burley tobacco.

[0171] Expanded stem tobacco production Tobacco stems obtained by green leaf deboning were moistened to a moisture content of 25-35% and then cut to a cutting width of 25-28 CPI. The cut stems were then expanded by steam treatment, which involved heating to a temperature of 180-250°C for 15 seconds to 3 minutes, resulting in evaporation of water within the tobacco cells and expansion of the tobacco. After steam treatment, the stem tobacco had a moisture content of 13-14%.

[0172] Tobacco processing 80 kg of DIET tobacco was packed into a single-walled corrugated box with external dimensions of 0.835 m x 1.120 m x 0.765 m, wrapped in a polyethylene liner (Polyliner®), and allowed to rest for a minimum of 30 days before being exposed to ambient processing conditions of 60°C and 60% relative humidity and a process time of 35, 37, or 39 days (for Sample A) or 35 days (for Sample R). The packing density of the tobacco before treatment was approximately 123 kg / m 3 It was.

[0173] 70 kg of expanded stalks were filled into C-48 boxes, wrapped in a polyethylene liner (Polyliner®), and left to stand for a minimum of 30 days before being exposed to ambient processing conditions of 60°C and 60% relative humidity and process times of 14, 21, or 28 days.

[0174] Taste evaluation Cigarettes containing untreated DIET, untreated expanded stems, treated DIET, or treated expanded stems were manufactured. A blind smoking test was then conducted by expert smokers. No significant differences in taste were observed for the treated expanded stems compared to the untreated expanded stems. However, an increase in spicy taste notes was observed for the treated DIET (for both Sample A and Sample R) compared to the untreated DIET. An increase in tannin taste notes was also observed for the treated Sample R DIET compared to the untreated control.

[0175] Thus, the taste characteristics of DIET tobacco, unlike other forms of expanded tobacco (expanded stems), were unexpectedly improved by the treatment.

[0176] Filling Value Analysis Filling values ​​of DIET tobacco were measured before and after treatment. Values ​​were corrected to match moisture content and values ​​quoted are for a reference moisture content of 13.5%.

[0177] [Table 1]

[0178] [Table 2]

[0179] Nicotine Analysis The nicotine content of the treated tobacco was analyzed by colorimetric method (continuous flow analysis using an AutoAnalyzer 3 instrument), and the analytical results are shown in Table 2.

[0180] [Table 3]

[0181] [Table 4]

[0182] From Table 2 it can be seen that the tobacco material contains a reduced amount of nicotine after treatment compared to before treatment.

[0183] Sugar Analysis The total sugar content of the processed tobacco was analyzed by colorimetric determination of all reducing substances and sucrose. The colorimetric method was continuous flow analysis using an AutoAnalyzer 3 instrument. The analytical results are shown in Table 3.

[0184] [Table 5]

[0185] [Table 6]

[0186] The results in Table 3 show that the sugar content of tobacco was reduced after treatment compared to before treatment.

[0187] Moisture Analysis To support the theory that sugars are being reduced in the tobacco material, the moisture content was analyzed before and after processing. Because the tobacco material was wrapped in a moisture-retaining material, no water was introduced into the tobacco material from the environment. Therefore, the increase in water / moisture observed after processing is likely caused by a reduction in sugars in the tobacco material.

[0188] [Table 7]

[0189] [Table 8]

[0190] Amino acid analysis Analysis of the treated tobacco using ultra-high pressure liquid chromatography (UPLC) equipped with a Q-TOF (quadrupole time-of-flight) analyzer showed a significant reduction in amino acid content, as shown by the data presented in Table 5 below.

[0191] [Table 9]

[0192] [Table 10]

[0193] Carotenoid analysis Analysis of the treated tobacco showed a significant increase in carotenoid content, as shown by the data presented in Table 6 below.

[0194] [Table 11]

[0195] [Table 12]

[0196] Example 2 Virginia leaf tobacco was treated for 39 days according to the method set forth in Example 1 for Sample A. After treatment, the temperature of the DIET tobacco was 64°C. The temperature of the tobacco was then gradually reduced to 22°C over a 40-day stabilization period. Large clumps of tobacco were observed within the treated DIET material. The properties of the tobacco after the stabilization period are shown in the table below (Test 1).

[0197] After the stabilization period, the DIET tobacco had a moisture content (OV) of 14% and a fill value of 6.8 cc / g. The percentage of tobacco that did not pass through a 2.5 cm x 2.5 cm mesh was 40% by weight.

[0198] In Test 2 below, immediately after treatment, the tobacco material was conveyed through a first set of doffers in the form of rollers with multiple rods protruding from their surfaces, and then through a second set of doffers in the form of rollers with multiple rods protruding from their surfaces. The spacing between the protruding rods on the first set of doffers was greater than the spacing between the protruding rods on the second set of doffers. In Test 3 below, the tobacco material was conveyed through the second set of doffers a second time. In Test 4 below, the tobacco material was conveyed through the second set of doffers a third time. The cooling time for Tests 2-4 was 30 minutes or less. Figure 4 shows the treated diet passing through the doffer sets.

[0199] [Table 13]

[0200] Cigarettes containing untreated DIET, untreated expanded stems, treated DIET, or treated expanded stems were manufactured. A blind smoking test was then conducted by expert smokers. The expert smokers determined that there was no significant difference in the sensory profile between the cigarettes containing tobacco produced in Tests 2, 3, and 4 and the control sample (cigarettes containing tobacco produced in Test 1).

Claims

1. 1. A method of producing dry ice expanded tobacco for use in a combustion aerosol delivery system, comprising the step of exposing dry ice expanded tobacco encapsulated in a moisture-retaining material to an ambient processing temperature of greater than 45°C, wherein the tobacco material is heated to a temperature of 60 to 160 kg / m at the start of the method. ３ and having a moisture content of about 10% to 23% before and during processing.

2. The tobacco material is at a concentration of 90 to 135 kg / m at the start of the process. ３ The method of claim 1 having a packing density of

3. The tobacco material is at a concentration of 100 to 130 kg / m at the start of the process. ３ 3. The method of claim 2, wherein the granules have a packing density of

4. The method of any one of claims 1 to 3, wherein the dry ice expanded tobacco comprises leaf tobacco.

5. 5. The method of claim 4, wherein the leaf tobacco comprises Virginia tobacco, e.g., the leaf tobacco is Virginia tobacco or a blend of Virginia and Burley tobacco.

6. 6. The method of claim 4 or 5, wherein the dry ice expanded tobacco consists of or consists essentially of the leaf tobacco.

7. The processed tobacco material is at least 6 cm thick at 13.5% moisture. ３ The method according to any one of claims 1 to 6, wherein the hydroxybenzoate has a loading value of 0.1g / g.

8. 8. The method of any one of claims 1 to 7, comprising dry ice expansion of a tobacco material to provide the dry ice expanded tobacco prior to exposing the dry ice expanded tobacco to the ambient processing temperature.

9. 9. The method of any one of claims 1 to 8, wherein the tobacco material has a moisture content of about 10% to 15.5% before and during processing.

10. 10. The method of any one of claims 1 to 9, wherein the tobacco material is exposed to the ambient processing temperature for 5 to 65 days.

11. 11. The method of any one of claims 1 to 10, wherein the microbial content of the treated tobacco material is lower than the microbial content of untreated tobacco material.

12. 12. The method of any one of claims 1 to 11, wherein the temperature of the tobacco material reaches the ambient processing temperature within about 4 to 10 days.

13. 13. The method of any one of claims 1 to 12, wherein the temperature of the tobacco material reaches a second temperature that is higher than the ambient processing temperature, for example, the second temperature is at least 2°C higher than the ambient processing temperature.

14. 14. The method of claim 13, wherein the second temperature is reached within about 7 to 13 days.

15. 15. The method of any one of claims 1 to 14, which results in a reduction in the content of at least one compound selected from the group consisting of nicotine, reducing sugars, non-reducing sugars, and amino acids in the treated tobacco material.

16. The method of any one of claims 1 to 15, essentially without fermentation.

17. Ambient processing humidity is about 50 to 500 g water / m when the ambient processing temperature is about 100°C or higher. ３ , about 50-340 g water / m at an ambient processing temperature of about 90°C ３ , about 50-230 g water / m at an ambient processing temperature of about 80°C ３ , about 50-160 g water / m at an ambient processing temperature of about 70°C ３ , about 50-110 g water / m at an ambient processing temperature of about 60°C ３ , or about 40-80 g water / m for an ambient processing temperature of about 55°C. ３ The method according to any one of claims 1 to 16, wherein

18. 18. A method according to any preceding claim, wherein the moisture-retaining material is wrapped around the tobacco material, for example, the moisture-retaining material comprises a flexible polymeric material, for example, the flexible polymeric material comprises polyethylene.

19. 19. The method of any one of claims 1 to 18, wherein the tobacco material is placed in a chamber to control the ambient processing temperature and / or ambient relative processing humidity.

20. 20. The method of any one of claims 1 to 19, further comprising breaking up clumps of tobacco material formed during processing of the dry ice expanded tobacco.

21. 21. The method of claim 20, comprising passing the treated DIET through one or more rollers having a plurality of teeth, spikes and / or protruding rods on their surfaces.

22. 22. The method of any one of claims 1 to 21, wherein during the method, the dry ice expanded tobacco reaches a temperature ("TX") that is at or above the ambient processing temperature, and thereafter the dry ice expanded tobacco is cooled from temperature ("TX") to a temperature of 30°C or below, for example from about 18°C ​​to about 30°C, from about 20°C to about 25°C, or about 22°C, over a period of 0.05 to 3 hours, such as from 0.1 to 2 hours, for example from 0.15 to 1 hour or from 0.2 to 0.7 hours.

23. Treated dry ice expanded tobacco obtainable by the method according to any one of claims 1 to 22.

24. 24. A component for use in a combustion aerosol delivery system, comprising the treated dry ice expanded tobacco material of claim 23.

25. 25. An article for use in a combustion-based aerosol delivery system, comprising the component of claim 24.

26. 26. A combustion aerosol delivery system comprising the treated dry ice expanded tobacco of claim 23, the component of claim 24, or the article of claim 25.

27. 24. Use of the treated dry ice expanded tobacco material of claim 23 to manufacture a component for use in a combustion aerosol delivery system.

28. 28. The component of claim 24, the article of claim 25, the combustion aerosol delivery system of claim 26, or the use of claim 27, wherein the combustion aerosol delivery system is a cigarette, a cigarillo, or a cigar.

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