Method for converting tobacco granules into non-continuous tobacco material

Abstract

A method for processing tobacco granules into a discontinuous tobacco material is provided. The method includes the steps of providing pre-sized stem tobacco material having a Dp90 particle size of less than 2.5 mm and a Dp50 particle size of 0.7 mm to 1.5 mm, and combining the pre-sized stem tobacco material with tobacco granules to produce a tobacco initial material, wherein the tobacco initial material comprises 40% to 60% (by weight) of the pre-sized stem tobacco material. The method may also include the steps of treating the initial material by bringing the initial material to a predetermined increased moisture content, subjecting the initial material to an elevated temperature, and subjecting the initial material to an elevated pressure, to combine the tobacco granules with the stem tobacco material, and transporting the initial material by a conveyor operating at a throughput of greater than 100 kg / hr.

Description

[Technical field]

[0001] The present invention relates to a method for converting tobacco granules into a non-continuous tobacco material, and to components, products and smoking articles that include the non-continuous tobacco material.

[0002] It is known that reprocessing of tobacco granules at various points during tobacco processing (e.g., transportation, tobacco preparation, cigarette manufacturing) can result in meaningful uses. For example, tobacco granules can be used as one of the initial materials for tobacco reconstitution (e.g., to produce reconstituted tobacco). Such processes typically allow for the production of continuous bodies of tobacco material (films, sheets, yarns, etc.).

[0003] Patent specification DE10065132A1 discloses a method for producing agglomerates from tobacco dust.

[0004] According to a first aspect of the present disclosure, there is provided a method for processing tobacco granules into a non-continuous tobacco material, comprising the steps of: Providing a pre-sized stem tobacco material having a Dp90 particle size of less than 2.5 mm and a Dp50 particle size of 0.7 mm to 1.5 mm; combining the pre-sized stem tobacco material with tobacco granules to produce a tobacco initial material; treating the initial material by bringing the initial material to a predetermined increased moisture content, subjecting the initial material to an increased temperature, and subjecting the initial material to an increased pressure to bond the tobacco granules with the stem tobacco material; the step of processing the initial material includes transporting the initial material by a conveyor operated at a throughput of greater than 100 kg / hr; The method further comprises the step of feeding the treated tobacco material through a shearing gap such that the treated tobacco material is defibrated by expansion, wherein the shearing gap is disposed between the shearing surfaces, and wherein the rotating shearing member comprises one of the shearing surfaces, and wherein the shearing member comprises at least 140 grooves, each groove having a maximum width of 0.7 mm to 1 mm in a circumferential direction of the shearing member.

[0005] The pre-sized petiole material may have a Dp90 particle size of less than 2.9 mm, preferably less than 2.8 mm, less than 2.7 mm, less than 2.6 mm, less than 2.5 mm, less than 2.4 mm, less than 2.3 mm, less than 2.2 mm, less than 2.1 mm or less than 2 mm. The pre-sized petiole material may have a Dp50 particle size of less than 1.9 mm, optionally less than 1.8 mm, less than 1.7 mm, less than 1.6 mm, less than 1.5 mm, less than 1.4 mm, less than 1.3 mm, less than 1.2 mm, less than 1.1 mm or less than 1 mm. The pre-sized petiole material may have a Dp10 particle size of at least 100 microns, optionally at least 150, 200, 250, 300 or 350, 400 or 500 microns.

[0006] The step of providing a pre-sized stem tobacco material may include providing a starter stem material and reducing the particle size of the starter stem material using a hammer mill.

[0007] The increase in temperature can be obtained by applying external heat and / or is the result of applying mechanical pressure.

[0008] The initial material may further include a winnowing.

[0009] The tobacco granules may have a particle size of less than 1 mm, optionally less than 0.5 mm.

[0010] The tobacco granules may be mechanically bonded to the pre-sized stem tobacco material without the use of any externally added binder, hi some embodiments, the tobacco granules are bonded by natural binders or by binders inherent in the tobacco granules and / or the stem tobacco material.

[0011] The material to be processed may be processed by continuously transporting the material.

[0012] The step of processing the initial material may include transporting the initial material through a conveyor that increases the mechanical pressure. The conveyor may include an extruder. The conveyor may be operated at a throughput of more than 100 kg / hr, preferably at least 110 kg / hr, preferably at least 115 or 120 kg / hr.

[0013] In some embodiments, the material to be processed is processed in batches.

[0014] The method may include preconditioning the petiole material and / or winnowing to one or more of the following parameters: temperature: 80-147°C, humidity: in the range of 6-14% OV by weight, and pressure (gas overpressure): 0-8 bar.

[0015] The method may comprise the step of preconditioning the petiole material and / or the winnowing to one or more of the following parameters: temperature: 100-120°C, humidity: in the range of 8-12% OV by weight, and pressure (gas overpressure): 0-3 bar, preferably 0-1 bar.

[0016] The step of treating the initial material includes bringing the initial material to a moisture content in the range of 10-50% OV (oven volatiles) by weight.

[0017] In some embodiments, the step of treating the initial material comprises bringing the initial material to a moisture content of at least 10% (oven volatiles). In some embodiments, the step of treating the initial material comprises bringing the initial material to a moisture content of 50% OV (oven volatiles) or less. In some embodiments, bringing the initial material to a predetermined moisture content occurs prior to feeding the treated tobacco material through the shirring gap.

[0018] The step of treating the initial material may comprise heating the initial material to a temperature in the range of 60-180°C, preferably in the range of 100-140°C, preferably in the range of 110-130°C.

[0019] In some embodiments, the step of treating the initial material comprises heating the initial material to a temperature of at least 60° C., preferably at least 100° C. or at least 110° C. In some embodiments, the step of treating the initial material comprises heating the initial material to a temperature of no more than 180° C., preferably no more than 140° C., preferably no more than 130° C. In some embodiments, heating the initial material to a predetermined temperature occurs prior to feeding the treated tobacco material through the shirring gap.

[0020] The step of treating the initial material may comprise pressurising the initial material to a pressure in the range of 10 to 200 bar, preferably in the range of 40 to 150 bar, preferably in the range of 60 to 120 bar.

[0021] In some embodiments, the step of treating the initial material comprises pressurizing the initial material to a pressure of at least 10 bar, preferably at least 40 bar, preferably at least 60 bar. In some embodiments, the step of treating the initial material comprises pressurizing the initial material to a pressure of no more than 200 bar, preferably no more than 150 bar, preferably no more than 120 bar. In some embodiments, pressing the initial material to a predetermined pressure occurs prior to feeding the treated tobacco material through the shearing gap.

[0022] The non-continuous tobacco material may be a fibrous and / or granular material.

[0023] The tobacco initial material may comprise at least 30% (by weight) of tobacco granules, preferably at least 35% (by weight) or at least 40% (by weight) of tobacco granules.

[0024] The tobacco initial material may comprise up to 50% (by weight) of tobacco granules, preferably up to 45% or up to 45% (by weight) of tobacco granules.

[0025] In embodiments in which the tobacco fines material comprises exogenous tobacco and / or other plant matter, the tobacco initial material may comprise up to 70% (by weight) of tobacco fines, preferably up to 65% (by weight) or up to 60% (by weight) of tobacco fines.

[0026] The tobacco initial material may comprise at least 5% (by weight) of tobacco winnowing, preferably at least 7%, 8%, 9% or 10% (by weight) of tobacco winnowing.

[0027] The tobacco initial material may contain no more than 20% (by weight) of winnowing, preferably no more than 18% (by weight), no more than 15% (by weight), no more than 12% (by weight), or no more than 10% (by weight) of winnowing.

[0028] The tobacco initial material may comprise 40-60% (by weight) of pre-sized stem tobacco material or at least 30% (by weight) of pre-sized stem tobacco material, preferably at least 40%, 45% or 50% (by weight) of pre-sized stem tobacco material.

[0029] The tobacco initial material may comprise up to 70% (by weight) of pre-sized stem tobacco material, and preferably up to 60% (by weight), up to 55% (by weight), or up to 50% (by weight) of pre-sized stem tobacco material.

[0030] The tobacco granules may comprise, consist of, or consist essentially of tobacco factory dust.

[0031] The tobacco granules may include extraneous tobacco and / or other botanical matter. For example, the tobacco granules may include, in addition to tobacco material, 30-50%, preferably about 40%, extraneous tobacco, and 20-40%, preferably 25-31%, other botanical matter. In some embodiments, the tobacco granules may include extraneous tobacco, such as Rajangan and / or Krosok tobacco, as well as kretek material, which may include clove dust. For example, the tobacco granules may include, consist of, or consist essentially of tobacco plant dust generated in the manufacture of kretek smoking articles.

[0032] The tobacco granules may have a Dp50 particle size of less than 1 mm, preferably less than 0.5 mm.

[0033] The method may include the step of exposing the treated tobacco material to a pressure drop resulting in flash evaporation.

[0034] The method may include feeding the treated tobacco material through a shirring gap such that the treated tobacco material is defibrated by expansion.

[0035] The shirring gap may have a width in the range of 10 to 2000 microns, preferably in the range of 50 to 300 microns.

[0036] The shirring gap may be disposed between the shirring surfaces, and the rotating shirring member comprises one of the shirring surfaces.

[0037] The shirring member may include a plurality of grooves, optionally including at least 80 grooves, optionally at least 90, 100, 120, 140, 160 or 180 grooves. Each groove may have a maximum width of up to 2 mm, optionally up to 1.5 mm or 1 mm.

[0038] The grooves may each have a maximum width of at least 0.3 mm, optionally at least 0.5 mm, 0.7 mm or 1 mm.

[0039] The method may include rotating the shirring member at an angular velocity of at least 10 rpm, preferably at least 100 rpm, 300 rpm, 300 rpm or 350 rpm. In some embodiments, the method includes rotating the shirring member at an angular velocity of 700 rpm or less.

[0040] The non-continuous tobacco material may have an average fiber diameter of less than 0.9 mm, preferably less than 0.8 mm. The non-continuous tobacco material may have a fiber diameter of less than 350 to 600 kg / m 3 The density index may range from 0.01 to 0.01.

[0041] According to a second aspect of the present disclosure, there is provided a non-continuous tobacco material produced by the method of the first aspect above.

[0042] According to a third aspect of the present disclosure, there is provided a component for a delivery system comprising a non-continuous tobacco material produced by the method of the first aspect above.

[0043] The component may further include a second tobacco material, which may preferably be cut rag tobacco.

[0044] The non-continuous tobacco material can be configured such that, by including the non-continuous tobacco material, delivery of tar during use of the component is increased compared to when the component does not include the non-continuous tobacco material.

[0045] The non-continuous tobacco material may be configured such that the inclusion of the non-continuous tobacco material increases tar delivery by at least 1.5% (by weight), 2% (by weight) or 2.5% (by weight) during use of the component for every 5% (by weight) of non-continuous tobacco material.

[0046] By including the non-continuous tobacco material, the delivery of nicotine during use of the component can be increased compared to when the component does not include the non-continuous tobacco material.

[0047] The non-continuous tobacco material may be configured such that the inclusion of the non-continuous tobacco material increases nicotine delivery by at least 1.5% (by weight), 2% (by weight) or 2.5% (by weight) during use of the component for every 5% (by weight) of non-continuous tobacco material.

[0048] By including non-continuous tobacco material, carbon monoxide delivery may be reduced during use of the component compared to if the component did not include the non-continuous tobacco material.

[0049] By including non-continuous tobacco material, the ratio of carbon monoxide to tar delivery during use of the component can be reduced compared to if the component did not include the non-continuous tobacco material.

[0050] The non-continuous tobacco material may be configured such that the inclusion of the non-continuous tobacco material reduces the ratio of carbon monoxide delivery to tar during use of the component by at least 1.5% (by weight), 2% (by weight), or 2.5% (by weight) for every 5% (by weight) of non-continuous tobacco material.

[0051] The components may include a tobacco rod for a combustible aerosol delivery system.

[0052] The inclusion of non-continuous tobacco material may result in a lower pressure drop across the component during use of the component compared to if the component did not include the non-continuous tobacco material.

[0053] The components may comprise tobacco material comprising a non-continuous tobacco material and a second tobacco material, wherein at least 4.5%, 5.5% or 6.5% (by weight) of the tobacco material is non-continuous tobacco material produced by the method of the first aspect above, and optionally at least 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19% or 20% (by weight) of the tobacco material is non-continuous tobacco material produced by the method of the first aspect above.

[0054] The component may be for an aerosol delivery system.The component may be a tobacco rod for a cigarette, cigar or cigarillo.

[0055] The component may be for a non-combustible aerosol delivery system, and optionally includes tobacco material, wherein at least 5% (by mass) of the tobacco material is non-continuous tobacco material produced by the method of the first aspect above.

[0056] The component may be a tobacco rod.

[0057] According to a fourth aspect of the present disclosure, there is provided an article of manufacture comprising a component according to the third aspect above.

[0058] According to a fifth aspect of the present disclosure there is provided a smoking article comprising a component according to the third aspect above.

[0059] Embodiments will now be described, by way of non-limiting example only, with reference to the drawings in which: [Brief description of the drawings]

[0060] [Figure 1] 1 is a flow chart illustrating an embodiment of a method for converting tobacco granules into a non-continuous tobacco material. [Diagram 2] 4 is a flow chart illustrating another embodiment of a method for converting tobacco granules into a non-continuous tobacco material. [Diagram 3] FIG. 1 is a schematic diagram of an embodiment of a pressure fiberization device. [Figure 4] FIG. 1 is a schematic diagram of a pressure regulation and fiberization system. [Diagram 5] FIG. 13 is a schematic diagram of another embodiment of a pressure regulation and fiberization system. Detailed Description

[0061] Referring to FIG. 1, a method of converting tobacco granules into a non-continuous tobacco material is shown.

[0062] The non-continuous tobacco material produced by the method can then be incorporated into a product. The product can be a component for a delivery system, such as an aerosol delivery system, described herein. In some embodiments, the aerosol delivery system is a combustible aerosol delivery system or a non-combustible aerosol delivery system. The component can be, for example, a tobacco rod. In one particular embodiment, the component is a tobacco rod for a cigarette or tobacco heating system. The product can be an article for use in a combustible aerosol delivery system, such as a cigarette, cigarillo, cigar, or cigarette for a pipe or a hand-rolled or homemade cigarette. Alternatively, the product can be an article for use in or with a non-combustible aerosol delivery system that releases a compound from an aerosol-generating material without burning the aerosol-generating material to generate an aerosol using a combination of aerosol-generating materials, such as an electronic cigarette, a heated tobacco product, and a hybrid system. Alternatively, the product may be for use in or with aerosol-free delivery systems that deliver at least one substance, which may or may not contain nicotine, to a user orally, nasally, transdermally or otherwise without forming an aerosol, including, but not limited to, lozenges, gums, patches, articles containing inhalable powders, and oral products including snus or snuff.

[0063] A method for processing tobacco granules into a non-continuous tobacco material includes the steps of (S1) providing a pre-sized stem tobacco material having a Dp90 particle size of less than 3 mm and a Dp50 particle size of less than 2 mm, (S2) combining the pre-sized stem tobacco material with the stem tobacco material to form a tobacco initial material, and (S3) treating the initial material by bringing the initial material to a predetermined increased moisture content, subjecting the initial material to an increased temperature, and subjecting the initial material to an increased pressure, so as to bond the tobacco granules with the stem tobacco material.

[0064] Pre-sized stem material refers to stem tobacco material that has been subjected to a pre-sizing step prior to combining the stem material with tobacco granules to form the initial material.

[0065] In some embodiments, the step of providing a pre-sized stem tobacco material includes providing a material having a Dp90 particle size of less than 2.5 mm and a Dp50 particle size of between 0.7 mm and 1.5 mm.

[0066] In some embodiments, the pre-sized stem tobacco material has a particle size of less than 3 mm or less than 2 mm. In one embodiment, the pre-sizing step involves passing the stem material through a 3 mm or 2 mm sieve and discarding or processing any material that does not pass through the sieve to reduce its size.

[0067] It has been found that pre-sizing the petiole material to a Dp90 value of less than 3 mm and a Dp50 value of less than 2 mm improves the quality, particularly the consistency of the produced non-continuous material and the stiffness of the material to mechanical stress. This means that a large amount of non-continuous material can be included in the components or products described herein, such as components for aerosol delivery systems, without sacrificing the quality of the components or products, including the organoleptic properties of the components or products. Thus, a large amount of winnowings and tobacco granules can be recycled. It has also been found that such pre-sized petiole material means that the pressure fiberizer device can be operated at a higher throughput, so that a larger amount of non-continuous material can be produced per hour. The production of non-continuous material is also more repeatable and consistent. In some embodiments, the pressure fiberizer device operates at a throughput of at least 100 kg / hr, preferably at least 110, 115 or 120 kg / hr.

[0068] In addition, pre-sizing the petiole material means that larger petiole material, e.g., longer or mixed stalks, can be utilized and processed to have a Dp90 particle size of less than 3 mm and a Dp50 particle size of less than 2 mm, e.g., a Dp90 particle size of less than 2.5 mm and a Dp50 particle size of 0.7 mm to 1.5 mm, such that the process does not rely on the availability of short stalks.

[0069] Pre-sizing the petiole material also results in fewer "flakes" in the produced non-continuous material, as described in more detail below.

[0070] It has also been found that pre-sizing the stem material reduces the separation of the stems and the tobacco granules during mixing and processing, for example, in a mixing silo. The stem material and the tobacco granules, particularly the tobacco dust, have different particle sizes and shapes, which generally result in the stem material floating to the top while the dust collects at the bottom. This demixing can cause variability in the amount of the stems and the tobacco granules delivered to the fiberizer because the ratio of the granules delivered to the fiberizer decreases with each increase in the ratio of the stems. It has been found that pre-sizing reduces the said separation of the stems and the tobacco plant dust in the mixing silo, thus resulting in the production of a non-continuous material of a more consistent and stable density.

[0071] In some embodiments, the pre-sized petiole material has a Dp90 value of less than 2.9 mm, such as a Dp90 value of less than 2.8, 2.7, 2.6, 2.5, 2.4, 2.3, 2.2, 2.1 or 2 mm. In some embodiments, the Dp90 value may be less than 1.9, 1.8, 1.7, 1.6 or 1.5 mm.

[0072] The Dp90 value refers to the particle size value below which 90% by mass of the petiole material is smaller. For example, if the Dp90 value is 3 mm, then 90% (by mass) of the pre-sized petiole material has a particle size of less than 3 mm.

[0073] In some embodiments, the pre-sized petiole material has a Dp50 value of less than 1.9 mm, such as a Dp50 value of less than 1.9, 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1, or 1 mm. In some embodiments, the pre-sized petiole material has a Dp50 value of less than 0.9 or 0.8 mm. Alternatively or additionally, the Dp50 value may be greater than 0.5 mm, 0.6 mm, or 0.7 mm. In some embodiments, the Dp50 value is between 0.7 mm and 1.5 mm.

[0074] The Dp50 value refers to the particle size value below which 50% by mass of the petiole material is smaller. For example, if the Dp50 value is 2 mm, then 50% (by mass) of the pre-sized petiole material has a particle size less than 2 mm.

[0075] Smaller Dp50 and Dp90 values ​​indicate smaller particle size and therefore less separation of the pre-sized stem material from other components of the initial tobacco material and less flakes in the produced non-continuous tobacco material.

[0076] In some embodiments, the step of pre-sizing the petiole material (S1) results in pre-sized petiole material having a Dp10 value of at least 100 micrometers, preferably at least 150, 200, 250, 300 or 350 micrometers. In some embodiments, the Dp10 value may even be at least 400 or 500 micrometers.

[0077] The Dp10 value refers to the particle size value below which 10% by weight of the petiole material is smaller. For example, if the Dp10 value is 100 micrometers, then 10% (by weight) of the pre-sized petiole material has a particle size below 100 micrometers. A larger Dp10 value indicates a reduced amount of dust, i.e., a lower density of the non-continuous tobacco material produced, meaning that less is extracted as winnowings.

[0078] In some embodiments, the step of preparing pre-sized petiole material (S1) comprises providing the petiole material to a pulverizing device configured to reduce the size of the petiole material. The pulverizing device may be a milling / cutting / shredding device. In one embodiment, the pulverizing device is a hammer mill. Hammer mills have been found to advantageously reduce the amount of dust generated. In another embodiment, the pulverizing device is a centrifugal cutter. In another embodiment, the pulverizing device is a shredder. The shredder may, for example, chop stalk and stem fibers.

[0079] In another embodiment, the petiole material is pre-sized without any milling / cutting / shredding of the petiole material, but instead classifying the petiole material by removing stalks with particle sizes outside a certain range. This pre-sizing may involve sieving the petiole material with a mesh having a mesh size of, for example, 3 mm, and discarding the petiole material that does not pass through the sieve. For example, if the Dp50 and / or Dp90 values ​​are still larger or smaller than the target values ​​(e.g., 3 mm), the material may be passed through additional sieves as necessary to remove overly large / small material until the target Dp50 and / or Dp90 values ​​are achieved, or material of a certain size may be added to achieve the target Dp50 and / or Dp90 values.

[0080] In some embodiments, the petiole material is presized to have a particle size of less than 2 mm (e.g., mesh size No. 10). In some embodiments, the petiole material is presized to have a particle size of less than 1.9 mm, 1.8 mm, 1.7 mm, 1.6 mm, or 1.5 mm. Presizing may be optical (e.g., using a microscope), using a sieve, or using a classifier or sieving machine. In one embodiment, the petiole material is presized to have a particle size of less than 1.68 mm (e.g., mesh size No. 12).

[0081] In some embodiments, the step (S2) of forming the initial tobacco material further comprises combining the pre-sized stem material with the tobacco granules having winnowings. Thus, in such embodiments, the initial tobacco material comprises tobacco plant dust, tobacco winnowings, and pre-sized stem tobacco material.

[0082] "Tobacco fines" refers specifically to tobacco particles that are conventionally considered problematic (e.g., from a taste standpoint) and that could otherwise simply be released by drawing or used to produce reconstituted tobacco (tobacco film). In particular, tobacco fines are smaller than the width of the cut end of the tobacco (e.g., less than 1 mm), and more specifically, tobacco fines are smaller than the width of the cut end of the tobacco (e.g., less than 0.5 mm). That is, tobacco fines have a particle size of less than 0.5 mm.

[0083] In some embodiments, the tobacco granules comprise, consist of, or consist essentially of tobacco factory dust.

[0084] "Tobacco factory dust" refers to fine dust produced as a by-product of tobacco processing and manufacturing of tobacco products such as cigarettes. Tobacco factory dust / tobacco dust has a particle size of less than 0.5 mm. In some embodiments, tobacco factory dust has a Dp50 of 125 micrometers. This means that 50% by weight of the tobacco dust has a particle size of less than 125 micrometers.

[0085] "Tobacco granules" refers to material consisting of, or consisting essentially of, tobacco, and also includes tobacco materials that contain exogenous tobacco and / or mixtures of tobacco with other botanical matter.

[0086] "Plant matter" refers to any material that is derived from a plant.

[0087] "Tobacco" and "tobacco material" refer to any material derived from a plant of the Nicotiana genus.

[0088] "Other botanical substances" or "non-tobacco botanical substances" refers to any material derived from any plant that is not a plant of the genus Nicotiana. Thus, non-tobacco botanical substances include, but are not limited to, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, bay, licorice, matcha, yerba mate, orange skin, papaya, rose, sage, tea, such as green tea or black tea, thyme, cinnamon, cloves, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, Rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, bell pepper, mace, damiana, marjoram, olive, lemon balm, lemon basil, chives, caraway, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.Mint includes the following mint varieties: Mentha arventis, Mentha cv, Mentha niliaca, Mentha piperita, Mentha piperita citrata cv, Mentha piperita cv, Mentha spicata crispa, Mentha cardifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata cv and Mentha suaveolens. suaveolens).

[0089] The non-tobacco plant material may be cloves. For example, the clove material may include, but is not limited to, the following types of clove material: Jawa, Bali, Manado, and / or Manado sec.

[0090] Thus, in some embodiments, the tobacco granules comprise tobacco and non-tobacco plant matter. For example, the tobacco granules may comprise tobacco and clove materials.

[0091] The clove material may consist of, or consist essentially of, clove processing dust, which may be produced as a by-product during processing of clove buds.

[0092] The processing of the clove buds may include the following steps: 1.Isolation of clove vegetable matter; 2. Sifting; 3. Adjustment, for example with the aid of an adjusting screw and / or a temperature of about 70°C and a moisture content of 30-45% (for example 38%); 4. Bulking, e.g. in a bulking silo, for at least 3 hours; 5.Cutting; 6. Drying, e.g. with hot air, to a moisture content of less than 12%.

[0093] In a preferred embodiment, the clove material that may be present in the tobacco granules includes clove processing dust generated during the cutting step of clove bud processing. Preferably, the tobacco granules do not include materials generated during the separation of clove plant matter, for example due to the possible presence of foreign matter and / or unwanted silica content.

[0094] The use of clove material in tobacco granules can provide a unique flavor and sensory experience to the end user. Cloves are known to have sensory effects including, among others, flavor, spice, numbing, crackling, and throat soothing characteristics. Thus, the organoleptic properties of the non-continuous tobacco material produced by the disclosed method can be modified and improved.

[0095] The incorporation of cloves into tobacco materials has historical precedent in some regions and may be referred to as "kretek blends" or "kretek materials."

[0096] Thus, in some embodiments, the tobacco granules comprise kretek material. For example, the tobacco granules may comprise, consist of, or consist essentially of tobacco factory dust generated during the manufacture of smoking articles that include the kretek material.

[0097] The kretek material may contain 20-80% (by weight) tobacco, for example about 69-75% (by weight).

[0098] The kretek material may include exogenous tobacco material.

[0099] "Exotic tobacco" includes, but is not limited to, the following tobacco materials: Rajangan tobacco (which may be dark Rajangan tobacco or light Rajangan tobacco), Krosok, Madura, Maesan, Weleri, Pakpie Ploso, Temanggung, KASTURI, Boyolali, and / or Ploso.

[0100] The kretek material may contain 30-50% (by weight) extraneous tobacco, for example about 40% (by weight).

[0101] The kretek material may comprise clove material in an amount of 20-40% (by weight), for example 25-31% (by weight).

[0102] Thus, the tobacco granules may include a kretek blend material. By way of example, a mild kretek blend may have the following composition: Rajangan tobacco (38% by weight), stem tobacco material (14% by weight), Krosok tobacco (4% by weight), FCV / Oriental tobacco (19% by weight), and clove material (25% by weight).

[0103] As a further example, another kretek blend may have the following composition: Rajangan tobacco (30% by weight), stem tobacco material (11% by weight), Krosok tobacco (5% by weight), FCV / Oriental tobacco (23% by weight), and clove material (31% by weight).

[0104] Generally, the kretek blend may comprise 30-38% (by weight) Rajangan tobacco, 11-14% (by weight) stem tobacco material, 4-5% (by weight) Krosok tobacco, 19-23% (by weight) FCV / Oriental tobacco, and 25-31% (by weight) clove material.

[0105] In some embodiments, the tobacco granules include kretek material as defined herein and additional clove material. For example, the tobacco granules may include tobacco material, kretek material, and clove treated dust. The kretek material and clove treated dust may be present in the tobacco granules in a ratio of 40:5 to 50:1, for example a ratio of 47:3 (ratio of kretek material:clove treated dust by weight).

[0106] In some embodiments, the tobacco granules comprise tobacco dust, kretek material, and additional clove material, as defined herein. For example, the tobacco granules may comprise tobacco factory dust produced during the manufacture of smoking articles comprising tobacco material, kretek factory dust produced during the manufacture of smoking articles comprising kretek material, and clove processing dust produced as a by-product during the processing of clove buds.

[0107] Tobacco winnowings are roughly chopped stalk particles, midribs or stems, but may also include some blades and reconstituted sheets, and are typically considered undesirable in aerosol delivery systems due to their size and shape, and are sorted and removed from already chopped tobacco because they are believed to impair the quality of the aerosol delivery system, e.g., cigarettes. For this reason, traditionally, winnowings are typically recycled or discarded as waste.

[0108] Tobacco winnowing may refer to winnowing from cigarette manufacturing (CPP-winnowing = winnowing from cigarette manufacturing / packaging) or to winnowing from tobacco processing (TP-winnowing). The term "winnowing" hereinafter includes both winnowing obtained from cigarette manufacturing and for tobacco processing, unless otherwise specified.

[0109] In step (S3), the initial tobacco material is subjected to increased mechanical pressure, particularly elevated temperature and also humidity, in order to maintain adhesion of the tobacco granules to the stem tobacco material and the winnowings.

[0110] The initial tobacco material is brought to a predetermined increased moisture content and the material to be treated is subjected to an increased temperature, which can in particular be achieved by applying heat from the outside and / or by mechanically generating pressure.

[0111] In some embodiments, the tobacco initial material is heated to a temperature of between 60°C and 180°C, preferably between 100°C and 140°C, preferably between 110°C and 130°C.

[0112] In some embodiments, the tobacco initial material is subjected to a pressure of from 10 to 200 bar, in particular from 40 to 150 bar, preferably from 60 to 120 bar. Pressure, as used herein, refers to atmospheric pressure as defined above, unless otherwise specified.

[0113] In some embodiments, the residence time of the tobacco initial material may be less than 3 minutes, in particular less than 2 minutes, and preferably less than 1 minute.

[0114] As a result of step (S3), the tobacco granules bond to the stem material and winnowings, producing a non-continuous tobacco material that can be subsequently used in the manufacture of an aerosol delivery system. This eliminates the need for an expensive separate process. The tobacco granules are simply bonded / glued to the remaining material.

[0115] As a result of this process, there is a significant shift in the size distribution towards larger particles.

[0116] Thus, the tobacco initial material is subjected to mechanical pressure (e.g. in an extruder or conveyor screw conditioner) at elevated temperature and a defined moisture level. By means of the mechanical pressure, the tobacco granules are pressed onto the pre-sized stem tobacco material and winnowings and are intimately bonded thereto. As a result of this, the bond of the tobacco granules to the stem material and winnowings is very strong, and the tobacco material treated as proposed by the present invention is resistant to the normal pressures occurring during the manufacture of cigarettes, i.e. the tobacco granules no longer fall off when transported by air under normal manufacturing conditions. The mechanical stability is therefore higher than in the case of conventional tobacco film materials.

[0117] A higher proportion of tobacco fines in the tobacco initial material is advantageous because it means that more of the tobacco fines, which are normally an unwanted by-product of manufacturing, can be recycled instead of being discarded. In some embodiments, the tobacco initial material comprises at least 30% (by weight) of tobacco fines, preferably at least 35% (by weight) of tobacco fines.

[0118] In some embodiments, the tobacco initial material comprises 50% (by weight) or less tobacco fines, preferably 45% (by weight) or less tobacco fines or 40% (by weight) or less tobacco fines. It has been found that the use of 50% tobacco fines, preferably 45% or less tobacco fines or 40% or less tobacco fines is advantageous, as the use of larger amounts has been found to adversely affect the quality of the resulting non-continuous tobacco product, making the resulting non-continuous tobacco product denser and increasing the production of non-continuous tobacco that is extracted as winnowings.

[0119] In some embodiments, the tobacco initial material comprises tobacco fines in the range of about 30-50% (by weight). A tobacco initial material having a range of 30-50% achieves a good compromise between, on the one hand, using a beneficial amount of tobacco fines that would otherwise be wasted, and, on the other hand, using not too many tobacco fines that would otherwise negatively affect the quality of the resulting non-continuous tobacco material and become dense. Preferably, the tobacco initial material comprises tobacco fines in the range of about 35% (by weight) to 45% (by weight), preferably about 40% (by weight). The tobacco fines may comprise, consist of, or consist essentially of tobacco dust.

[0120] In some embodiments, the tobacco initial material comprises in the range of about 30-50% (by weight) tobacco dust, preferably in the range of 35% (by weight) to 45% (by weight) tobacco dust, preferably about 40% (by weight) tobacco dust.

[0121] In embodiments in which the tobacco granule material comprises exogenous tobacco and / or other plant matter, the tobacco initial material may comprise up to 70% (by weight) of tobacco granules, preferably up to 65% (by weight) or 60% (by weight) of tobacco granules.

[0122] In some embodiments, the tobacco initial material comprises at least 5% (by weight) of tobacco winnowing, preferably at least 7, 8, 9 or 10% (by weight) of tobacco winnowing. In some embodiments, the tobacco initial material comprises no more than 20% (by weight) of tobacco winnowing, preferably no more than 15% (by weight) of tobacco winnowing.

[0123] In some embodiments, the tobacco initial material comprises tobacco winnowing in the range of 5-20% (by weight), preferably in the range of 5-15% (by weight), preferably about 10% (by weight) of winnowing. In some embodiments, the winnowing is not pre-sized.

[0124] In some embodiments, the tobacco initial material comprises at least 30% (by weight) of pre-sized stem tobacco material, preferably at least 40% (by weight), 45% (by weight) or 50% (by weight) of pre-sized stem tobacco material.

[0125] In some embodiments, the tobacco initial material comprises 70% (by weight) or less of pre-sized stem tobacco material, preferably 65% ​​(by weight) or less, 60% (by weight) or less, or 55% (by weight) or less, or 50% (by weight) or less of pre-sized stem tobacco material.

[0126] In some embodiments, the tobacco initial material comprises in the range of 30-70% (by weight) of pre-sized stem tobacco material, preferably in the range of 40-60% (by weight) of pre-sized stem tobacco material, preferably about 50% (by weight) of pre-sized stem tobacco material.

[0127] In some embodiments, the tobacco initial material comprises 30-50% (by weight) of tobacco fines, 5-20% (by weight) of tobacco winnowing, and 30-70% (by weight) of stem tobacco material. However, it should be recognized that other amounts of tobacco fines, winnowing, and stem tobacco material are possible. Preferably, the initial material comprises 20-40% (by weight) of tobacco fines, 10-15% (by weight) of tobacco winnowing, and 40-60% (by weight) of stem tobacco material. More preferably, the initial material comprises 25-35% (by weight) of tobacco fines, 10-15% (by weight) of tobacco winnowing, and 45-55% (by weight) of stem tobacco material.

[0128] In some embodiments, the tobacco granules may comprise, consist of, or consist essentially of tobacco dust material, such as tobacco plant dust. The tobacco granules may include foreign tobacco and / or a mixture of tobacco and non-tobacco plant matter.

[0129] In embodiments in which the tobacco fines material comprises exogenous tobacco and / or other botanical matter, the tobacco initial material may comprise 30-70% (by weight) of tobacco fines, up to 20% (by weight) of tobacco winnowing, and 30-70% (by weight) of stem tobacco material. However, it should be appreciated that other amounts of tobacco fines, winnowing, and stem tobacco material are possible. Preferably, the initial material comprises 20-65% (by weight) of tobacco fines, 0-15% (by weight) of tobacco winnowing, and 40-60% (by weight) of stem tobacco material. More preferably, the initial material comprises 25-60% (by weight) of tobacco fines, 0-10% (by weight) of tobacco winnowing, and 35-55% (by weight) of stem tobacco material.

[0130] As a result of step (S3), no additional or exogenous binders need to be added to bind the tobacco granules to the tobacco stem and winnowings, neither extraneous nor intrinsic binders, i.e., binders naturally present in tobacco. Instead, the tobacco granules can be bound to the tobacco stem and winnowings mechanically and / or by a certain amount of binders naturally present in tobacco (intrinsic binders). Such intrinsic binders (e.g., starches, resins, and sugars) are activated, thus firmly binding the tobacco granules to the tobacco stem and winnowings. This is in contrast to methods that rely on the addition of binders, including methods that produce films or globs that rely on the addition of binders.

[0131] The processing preferably results in a product that is a non-continuous tobacco material, particularly a fibrous and / or granular material or filler. In other words, the method produces a product that is ready to be consumed to produce tobacco rods for, for example, cigarettes or tobacco heating devices, and can be used directly in an aerosol delivery system. This is very different from the production of tobacco film (continuous tobacco material), which is more complicated to manufacture and still requires post-manufacturing cutting and drying. The resulting product of the present disclosure has a size and moisture content that makes it suitable for direct use as a filler for aerosol delivery systems, including cigarettes and tobacco heating devices.

[0132] In some embodiments, the initial material is processed in batches, in particular batch pressed, for example in a piston-cylinder unit.

[0133] It has been discovered that the non-continuous tobacco material produced by the method of FIG. 1 has increased tar and nicotine delivery, reduced carbon monoxide delivery, reduced carbon monoxide to tar ratios, reduced pressure drop across components comprising non-continuous tobacco material, and reduced hardness and fill values ​​of components comprising non-continuous tobacco material.

[0134] Referring now to FIG. 2, another embodiment of a method for converting tobacco granules into a non-continuous tobacco material is shown.

[0135] The method of the embodiment of Figure 2 is similar to that of Figure 1, and includes the steps of (S1) preparing a pre-sized stem tobacco material having a Dp90 particle size of less than 3 mm and a Dp50 particle size of less than 2 mm, (S2) combining the pre-sized stem tobacco material with tobacco granules to form a tobacco initial material, and (S3) treating the initial material by bringing the initial material to a predetermined increased moisture content, subjecting the initial material to an increased temperature, and subjecting the initial material to an increased pressure, so as to bond the tobacco granules to the stem tobacco material. A detailed description of these steps (S1-S3) will not be repeated below.

[0136] The method of FIG. 2 further includes the steps of conditioning the stem material (SoA), conditioning the winnowing (SoB), feeding the initial material through a shirring gap to form a non-continuous tobacco material (S4), and cooling the non-continuous tobacco material (S5).

[0137] It should be appreciated that in some embodiments (not shown), one or more of steps (SoA), (SoB), (S1), (S2), (S3), (S4) or (S5) may be combined. By way of example, the initial tobacco material may be conditioned while in the feeding apparatus, for example brought to initial conditions (such as temperature, humidity and pressure), while moving through a screw feeder of the feeding apparatus, or may be conditioned in the fiberizer.

[0138] It should also be appreciated that in some embodiments (not shown), one or more of steps (SoA), (SoB), (S1), (S2), (S3), (S4) or (S5) may be ordered differently or omitted entirely. For example, the tobacco stems, winnowings and / or tobacco granules may be combined after conditioning. The petiole material may be conditioned before or after being subjected to the pre-sizing step (S1). However, in this example, the petiole material is conditioned before being subjected to the pre-sizing step (S1).

[0139] In steps (SoA) and (SoB), the petiole material and the winnowing, respectively, are subjected to one or more of the following initial conditions (pressure values ​​are always higher than atmospheric pressure): Temperature: 80 to 147°C, preferably 100 to 120°C Humidity: 6-14%, preferably 8-12% Pressure (gas overpressure): 0-8 bar, preferably 0-3 bar, preferably 0-1 bar.

[0140] That is, the petiole material is subjected to one, more than one, or all of the above conditions in step (SoA) and separately, the winnowing is subjected to one, more than one, or all of the above conditions in step (SoB). Step (SoA) may precede or follow step (SoB), or may occur simultaneously with step (SoB). In some embodiments, steps (SoA) and (SoB) are combined.

[0141] This preconditioning can be carried out under atmospheric conditions. Alternatively, in some embodiments, the preconditioning process is operated at pressures above atmospheric pressure, as described in patent specification DE10304629A1. During preconditioning and / or simultaneously during the process (above atmospheric pressure), casings and flavorings may be added in a manner known to those skilled in the art.

[0142] Preferably, in step (SoA), the petiole material is brought to all of the above initial conditions. Preferably, in step (SoB), the winnowing is brought to all of the above initial conditions.

[0143] The step (S3) of treating the initial material by bringing the initial material to a predetermined increased moisture content, subjecting the initial material to an increased temperature and subjecting the initial material to an increased pressure in order to bond the tobacco granules with the stem tobacco material is preferably operated with reference to one or more of the following parameters: Temperature: 80 to 180°C, preferably 125 to 156°C Humidity: 15-50%, preferably 18-45% Mechanical pressure: 80-250 bar, preferably 72-132 bar.

[0144] Preferably, step (S3) operates on the basis of all of the above parameters of temperature, humidity and mechanical pressure, in other words bringing the material to the above mentioned temperature, humidity and pressure values.

[0145] In step (S3), the tobacco initial material is subjected to an increase in pressure, as explained above. This increased pressure is reduced again in step (S4), when the initial material is fed through a shearing gap to form a non-continuous tobacco material. This typically occurs upon exiting a processing device (e.g. extruder, screw conveyor, piston-cylinder unit) that subjects the tobacco initial material to elevated temperature, pressure and humidity. This reduction in pressure on discharge from the shearing gap results in flash evaporation, which causes the material to expand. This advantageously enhances the filling capacity of the material.

[0146] In step (S3), the tobacco initial material is heated and placed under pressure to improve flavor through chemically engineered processes (e.g., Maillard reaction or caramelization) and also conserve energy to facilitate shirring and expansion through the shirring gap. The pressure generation and heating may be operated in a standard plug screw feeder, the housing of which may also be heated.

[0147] In some embodiments, the step of treating the initial material (S3) and / or the step of feeding the initial material through a shirring gap to form the non-continuous tobacco material (S4) is carried out using an apparatus configured as shown in FIG. 3.

[0148] In step (S4), feeding the initial material through the shirring gap to form the non-continuous tobacco material promotes the defibration of the material. In some embodiments, when exiting the shirring gap and entering the atmosphere, the entrained water and optionally other entrained components evaporate rapidly, which, in addition to the shirring effect, causes the defibration and expansion of the material in the shirring gap. The humidity of the material is reduced by flash evaporation to a range of 5-25%, preferably 10-20%, depending on the pressure and temperature of the process, and the components contained in the tobacco are also reduced to a certain extent. It has been found to be advantageous if the shirring gap surfaces move relative to each other to prevent and eliminate blockages. This ensures that the entire cross-section of the gap is used and that constant physical conditions prevail in the gap, ultimately resulting in a uniform product. To this end, it has also proven to be advantageous if the gap surfaces are structured or shaped, for example with grooves as described in detail below.

[0149] In step (S5), the tobacco material is cooled, for example from above 100°C to room temperature, which may be done on a conveyor belt based on air suction and operated from below. During the cooling process, the tobacco material loses more moisture due to evaporative cooling, which allows it to reach the moisture level of the final product without a dryer. The cooled tobacco material may have a moisture content, for example, in the range of 10-20%, preferably in the range of 13%-16%.

[0150] In some embodiments, after feeding the tobacco material through an expansion and drying process, the non-continuous tobacco material has a reduced moisture content, for example in the range of 10-20%, preferably in the range of 13%-16%.

[0151] The non-continuous tobacco material produced by the method of FIG. 2 has been found to have increased tar and nicotine delivery, reduced carbon monoxide delivery, reduced carbon monoxide to tar ratios, reduced pressure drop across components comprising the non-continuous tobacco material, and reduced hardness and fill values ​​of components comprising the non-continuous tobacco material.

[0152] These characteristics of the non-continuous tobacco material produced by the method of FIG. 2 were observed through the manufacture and comparison of 40 samples of the first and second types of cigarettes.

[0153] The first type of cigarette was a king size cigarette including a 21.8 mm long filter and a 60.8 mm long tobacco rod, which was manufactured from 100% non-continuous tobacco material produced by the method of Figure 2. It should be noted that cigarettes will typically contain only a small portion, e.g., 5% or 10%, of non-continuous tobacco material, as discussed above.

[0154] The second type of cigarette was a king size cigarette including a 21.8 mm long filter and a 60.8 mm long tobacco rod made from 100% cut rag tobacco wrapped in an outer wrap.

[0155] Both the first and second types of cigarettes have a tobacco rod having a circumference of 24.7 mm.

[0156] Additionally, the inclusion of non-continuous tobacco material resulted in a pressure drop across the component during smoking of the tobacco rod, as compared to when the tobacco rod did not include the non-continuous tobacco material.

[0157] The properties of the non-continuous tobacco material produced by the method of FIG. 2 were also observed by producing and comparing 40 samples of first and second types of cigarettes containing 25% chopped roll expanded stem (CRES).

[0158] The first type of cigarette was a king size cigarette including a 21.8 mm long filter and a 60.8 mm long tobacco rod made from a blend of 75% non-continuous tobacco material produced by the process of FIG. 2 with 25% chopped roll expanded stems (CRES).

[0159] The second type of cigarette was a king size cigarette including a 21.8 mm long filter and a 60.8 mm long tobacco rod made from a blend of 75% cut rag tobacco and 25% cut roll expanded stem (CRES) and wrapped in an outer wrap.

[0160] Both the first and second types of cigarettes have a circumference of 24.7 mm.

[0161] Forty cigarettes of the first type and forty cigarettes of the second type were then tested using an RM20H smoking apparatus that complies with ISO 4387 to measure tar, nicotine and carbon monoxide delivered per cigarette; the carbon monoxide to tar ratio; tar delivered per puff of each cigarette; and nicotine delivered per puff of each cigarette.

[0162] TIFF0007659621000001.tif107149

[0163] Table 2 above shows the average measurements for 40 cigarettes of the first type and the average measurements for 40 cigarettes of the second type. As before, the results show that the non-continuous tobacco material produced by the method of FIG. 2 has increased tar and nicotine delivery, reduced carbon monoxide delivery, lower carbon monoxide to tar ratios, and reduced pressure drop across the components that include the non-continuous tobacco material. This is shown despite the fact that both the cut rag tobacco and the non-continuous tobacco material are produced from the same type of tobacco. In other words, both the cut rag tobacco and the non-continuous tobacco material are derived from the same type of tobacco plant, but the non-continuous tobacco material includes a mixture of pre-sized stems, winnowings, and tobacco granules that are processed according to the method of FIG. 2.

[0164] 3, there is shown a processing apparatus 1. In this embodiment, the processing apparatus 1 is a pressure fiberization device 1.

[0165] The pressure fiberization device 1 comprises a chamber housing 2 in which is located a conveyor screw 3 which is rotated by means of a drive mechanism 4 , for example a motor 4 .

[0166] The pressure fiberization device 1 further comprises an inlet 5A for tobacco material, an inlet 6A for water, and an inlet 6B for a casing and / or a flavoring agent. The pressure fiberization device 1 may further comprise an inlet 7 for steam.

[0167] The tobacco initial material is fed to the tobacco material inlet 5A and enters the chamber housing 2, where it passes along the chamber housing 2 by rotation of the conveyor screw 3 such that the tobacco initial material passes from the tobacco material inlet 5A to the outlet 5B. At the outlet 5B of the chamber housing 2 is a head 8 which includes a generally conical recess 8A.

[0168] The shirring member 10 is received in the cavity 8A. A shirring gap 9 is formed between the shirring member 10 and the inner wall of the cavity 8A. The initial tobacco material is transported through the gap 9 by the screw 3. The outlet 5B of the chamber 2 is in the form of an orifice connecting the interior of the chamber 2 with the cavity 8A. The orifice may be located at the gap apex of the generally conical cavity 8A. The discharged defibrated tobacco material is designated by reference numeral 12.

[0169] In some embodiments, the shirring member 10 is in the form of a cone. The shirring gap 9 may be annular.

[0170] The shirring member 10 is coupled to an actuator mechanism 11 configured to rotate the shirring member 10. The shirring member 10 can rotate about its central axis, the rotation being indicated by the curved arrow in Figure 3. In some embodiments, the actuator mechanism 11 includes a motor.

[0171] In some embodiments, the actuator mechanism 11 is configured to axially move the shearing member 10 to adjust the size of the gap 9 .

[0172] The axial movement of the shearing member 10 is indicated by a double-headed arrow in FIG. 3, indicating that the shearing member 10 moves toward and away from the head 8. Thus, the shearing member 10 can remain fixed in its axial position, but can also move axially. As a result of this, the width of the gap 9 can be adjusted or adapted, and in some embodiments, a counter pressure can be created in the direction of closing the gap 9. The actuator mechanism 11 can be configured to move the shearing member 10 axially using a hydraulic or pneumatic actuator, or utilizing a linear gear arrangement, such as a rack and pinion gear arrangement driven by a motor.

[0173] The first part of the process of defibrating the tobacco stems is carried out under pressure above atmospheric pressure, in step (S3). This overpressure is created as soon as the initial tobacco material is fed into the inlet 5A and is transported along the chamber 2 via the screw 3.

[0174] A shirring gap 9 is disposed at the outlet end 5B of the chamber 2. The gap 9 essentially closes off the chamber 2 in the same manner as an extruder.

[0175] The gap 9 may be substantially annular in cross section. The width of the gap 9 in the axial direction of the conveyor screw is determined by the axial position of the shearing member 10. Thus, in embodiments in which the axial position of the shearing member 10 is adjustable, the width of the gap 9 is also adjustable.

[0176] In step (S3), the initial tobacco material is subjected to an increased pressure (up to 200 bar) and an increased temperature (particularly above 100° C.). In addition to the mechanical pressure caused by the transport of the initial tobacco material towards the gap 9, an additional force also acts on the initial tobacco material, due to the shear force acting on the pitch of the conveyor screw in conjunction with the wall, causing chopping and defibration of the initial tobacco material. The shearing effect can be assisted by introducing an air flow through the housing wall or by introducing additional flow resistance. In addition, steam may be introduced at several points to adjust the humidity, temperature and pressure in the conveyor screw or in the chamber 2. As a result of the introduction of steam, and due to the natural moisture content of the stems from the conditioning process, additional defibration of the initial tobacco material occurs, due to the rapid evaporation of water upon leaving the gap 9. Under pressure, the moisture in the initial tobacco material evaporates rapidly, because the pressure drops to atmospheric pressure downstream of the gap 9, thus causing flash evaporation.

[0177] In some embodiments, the initial tobacco material is placed under mechanical pressure, in particular mechanically pressed against the shearing gap 9 in chamber 2. This is the case when the material may be placed under pressure by means of a conveyor screw which presses the material towards the outlet end of chamber 2 of a heated screw conveyor in which the shearing gap 9 is located. The initial material may also be coarsely pre-chopped or coarsely pre-defibrated in chamber 2 at the same time as it is fed towards the shearing gap.

[0178] In some embodiments, the shirring gap 9 is closed under pretension and is intermittently opened by the pressure of the tobacco material as the material passes through the gap 9. Alternatively, the material may advantageously be fed through the shirring gap 9 which is continuously open.

[0179] In some embodiments, the shirring gap 9 has a width in the range of 50 to 300 micrometers.

[0180] In some embodiments, the pressure chamber 2 has a transport system in the form of a plug screw feeder for transporting the tobacco material from the inlet 5A to the outlet 5B. In some embodiments, the pressure is generated by mechanical means, for example as generated by a plug screw feeder, although other systems within the principles of the present disclosure may also be used, for example using a piston system, or may be generated non-mechanically or not only by the use of gas pressure, such as a supply of pressurized gas.

[0181] When using a plug screw feeder, in some embodiments it has fewer features, such as a smaller screw pitch, that reduce the chamber volume in the region towards the outlet.

[0182] In some embodiments, mechanical pre-scored or pre-fibrillation features are arranged in the pressure chamber 2. In one embodiment, a screw chamber pressure regulating device is arranged upstream of the device proposed by the present invention, in the same pressure chamber housing or in another pressure chamber housing connected upstream. This type of pressure regulating device is described, for example, in patent DE10304629A1 and can be combined with the pressure defibration device 1 of the present disclosure. The pressure regulating device 1 can incorporate all the structural features illustrated in FIG. 1 and are described in the relevant description of DE10304629A1, to which reference can be made for further details.

[0183] In some embodiments, the pressure chamber 2 includes inlets for modifiers or casing agents and flavoring agents.

[0184] The conditioning and pressure defibration process depends on the pressure conditions under which conditioning is performed. In some embodiments, the tobacco initial material is conditioned under atmospheric conditions and fed, for example, via a hopper, by means of a conveyor chute or conveyor belt into a feeding device, for example, inlet 5A. One or more components of the tobacco initial material may be conditioned separately. For example, the stem material and winnowings may be separated separately and then combined with each other and with the tobacco granules. In some embodiments, the stem material is conditioned before pre-sizing.

[0185] In some embodiments, the feeding apparatus includes a silo (not shown) and a screw feeder (not shown). The tobacco initial material is stored in the silo and fed by the screw feeder, where the screw feeder feeds the tobacco initial material to the inlet 5A of the pressure defibrator device 1.

[0186] The feeder may be configured to feed a predetermined flow rate of the tobacco initial material to the processing device 1. In some embodiments, the feeder is configured to feed the tobacco initial material to the processing device 1 at a flow rate in the range of 50-250 kg / h, preferably in the range of 95-175 kg / h.

[0187] The conditioning process can be carried out at the axial midpoint of chamber 2 by introducing water and casing at respective inlets 6A and 6B. In some alternative embodiments (not shown), the water and casing (and / or flavorings) are introduced at the same inlet, or only one of the water and casing is introduced into chamber 2.

[0188] In step (S4), the initial tobacco material passes through gap 9 and is subjected to shirring between the walls of head 8 and shirring member 10, and the above-mentioned flash evaporation occurs as the material exits gap 9. Gap 9 therefore acts as a shirring gap 9. Both shirring and flash evaporation contribute to a well-defibrated non-continuous tobacco product, which can be used in an aerosol delivery system.

[0189] In some embodiments, the shirring member 10 rotates about its axis of rotation, helping to prevent blockages from occurring at the gap 9. This rotation of the shirring member 10 may be continuous or intermittent, or may change direction of rotation. This is the case when the rotation may be a full rotation or only a quarter or third rotation or small / large increments of rotation. In an alternative embodiment (not shown), the shirring member 10 is fixed and the head 8 rotates, for example coupled to a drive mechanism. However, it should be appreciated that in further embodiments, the head 8 and the shirring member 10 do not rotate relative to each other.

[0190] In some embodiments, the head 8 and the shirring member 10 include shirring surfaces 13 and 14, respectively, where a gap 9 is formed between the shirring surfaces 13 and 14. In some embodiments, the shirring surfaces 13 and 14 are generally opposed.

[0191] In some embodiments, one or both of the shirring surfaces 13 and 14 have one or more surface formations, such as grooves or other roughness (such as ridges or indentations). In some embodiments, the surface formations, such as grooves, may have a radial depth of at least 0.2 mm or at least 1 mm. The surface formations may also promote shirring of the initial tobacco material and more uniform pressure conditions leading to a more uniform final product. In some embodiments, the grooves extend parallel to the central axis of the shirring member 10.

[0192] In some embodiments, the shirring member 10 includes more than 80 grooves, preferably at least 90, 100, 120, 140, 160, or 180 grooves.

[0193] In some embodiments, each groove has a maximum width in the range of 0.5-1.5 mm. The width of each groove may be constant or may vary. It has been found that the smaller the groove width, the smaller and lighter the fibers in the defibrated non-continuous tobacco material. The width of the groove is in the circumferential direction of the shirring member 10.

[0194] In some embodiments, the shirring surfaces 13 and 14 are movable away from and towards each other. In some embodiments, the shirring member 10 is biased with respect to the head 8 so that the shirring surfaces 13 and 14 are adjacent and thus the gap 9 is closed. Alternatively, the shirring surfaces 13 and 14 are movable away from and towards each other at a fixed or fixed adjustable distance, in which case the shirring surfaces 13 and 14 are located at a fixed distance of 10-2000 microns, preferably 50-300 microns. These figures refer to smooth shirring surfaces 13 and 14. Alternatively, if the shirring surfaces 13 and 14 include, for example, grooves, the distance refers to the distance between the portions of the surfaces 13 and 14 between each groove.

[0195] In some embodiments, the grooves of the shirring member 10 extend lengthwise or widthwise in the direction in which the shirring surfaces 13 and 14 move.

[0196] In some embodiments, the shirring surface 14 of the head 8 is fixed, while the shirring surface 13 of the shirring member 10 moves axially. In some embodiments, the shirring surface 14 of the head 8 moves axially, while the shirring surface 13 of the shirring member 10 remains fixed.

[0197] In some embodiments, the shirring surface 14 of the head 8 is fixed, while the shirring surface 13 of the shirring member 10 rotates. In some embodiments, the shirring surface 14 of the head 8 rotates, while the shirring surface 13 of the shirring member 10 remains fixed.

[0198] The rotation and axial translation of the shearing surfaces 13 and 14 can be caused by the same actuator mechanism 1. Alternatively, a first actuator mechanism can rotate one of the shearing surfaces 13 and 14, while a second actuator mechanism can axially translate said one or the other of the shearing surfaces 13 and 14.

[0199] In some embodiments, the shirring surfaces 13 and 14 move towards each other continuously or intermittently, or in one or more directions, or back and forth.

[0200] In some embodiments, the gap 9 may be an annular gap, preferably a conical gap.

[0201] In step (S5), the material is cooled. The material may be cooled, for example, while being transported on a conveyor belt.

[0202] The resulting defibrated product exhibits similar characteristics to shredded petioles in terms of appearance and use, however the pressure defibration process and the device of Figures 1-3 do not have the drawback of generating a large amount of dust, since this is the case when the petioles are shredded and do not require much moisture conditioning, and the subsequent drying can be dramatically reduced or eliminated.

[0203] In some embodiments, the produced non-continuous material has an average fiber diameter of less than 0.95 mm, preferably less than about 0.9 mm or 0.85 mm. In some embodiments, the average fiber diameter is about 0.8 mm or less. The average fiber diameter may be less than 0.8 mm. In some embodiments, the average fiber diameter is in the range of 0.6-0.8 mm. A smaller average fiber diameter results in a lighter non-continuous material, which has a lower density. It has been found that a lower density produced non-continuous material reduces the non-continuous material extracted as winnowings and also reduces the total tobacco material extracted as winnowings at the rod maker.

[0204] The produced non-continuous material may be a binder-free recycled material.

[0205] Pre-sizing the petiole material to a Dp90 particle size of less than 3 mm and a Dp50 particle size of less than 2 mm also reduces "flakes" in the non-continuous material produced. Flakes are produced when large unbroken petiole pieces pass over the grooves of the shirring member and exit the chamber of the fiberizer. These flakes often have a particle size larger than the width of one or two grooves of the shirring member and may have a diameter equivalent to a regular or king size cigarette. Flakes are relatively light and therefore generally not extracted as winnowings, which may adversely affect the taste of the final product and may cause an elevated pressure drop in the aerosol delivery system, e.g., cigarettes. If the non-continuous material produced is formed into a rod, the flakes may cause inconsistencies in the rod formation and therefore may adversely affect the final stability of the rod, meaning that more non-continuous material falls off the end of the rod. Pre-sizing the petiole material reduces the flakes and therefore alleviates these problems.

[0206] Referring now to Figure 4, another embodiment of a processing apparatus is shown. The processing apparatus comprises a pressure fiberization device 1 of the type described above with reference to Figure 3. The processing apparatus further comprises a pressure regulation device 20 connected upstream of the pressure fiberization device 1.

[0207] The pressure fiberization device 1 and the pressure regulating device 20 form part of a combined pressure regulating and fiberization system.

[0208] The pressure regulating device 20 may in particular be of the type illustrated in FIG. 1 of the present specification DE10304629A1 and described in the relevant parts of the description thereof, the latter being included herein by reference. It has an inlet 25 for tobacco material and a pressure-resistant cellular wheel sluice 26, through which the tobacco initial material is introduced into the pressure chamber 21, where it is conveyed with the aid of a conveyor screw 22. The conveyor screw 22 is driven by a drive mechanism, for example a motor 24.

[0209] At the end of the chamber 21 there is an outlet 27 for the tobacco material, which feeds into the inlet 5A of the pressure defibrator device 1. In some embodiments, unlike the device described in patent specification DE10304629A1, there is no differential pressure sluice at the outlet of the pressure regulating device. Instead, the tobacco initial material is conveyed to the inlet 5A of the pressure defibrator device 1 by the pressure of the chamber 22.

[0210] In other embodiments, the outlet from the pressure regulating device 22 is operated using a cellular wheel sluice to reduce the pressure. In such embodiments, the tobacco material may be transferred to the pressure defibration process at a pressure in the pressure regulating chamber, e.g., below atmospheric pressure. In some embodiments, the initial tobacco material is first processed by the pressure regulating device 20 and then transported to another pressure defibration device 1. The initial tobacco material can be transported between the pressure regulating device 20 and the pressure defibration device 1 manually or automatically, e.g., using a conveyor belt or air conveyor.

[0211] However, it is preferable to avoid pressure drops during the transfer from the pressure regulation device 20 to the pressure defibration device 1, as illustrated in Fig. 4, allowing the application of a pressure higher than atmospheric throughout the entire treatment area, from the start of regulation to the defibration process. The tobacco initial material is fed through a differential pressure resistant cellular wheel sluice 26. The pressure resistance of the sluice 26 at one end during operation and the gap 9, which is always filled with defibrated tobacco material, allows the maintenance of a pressure higher than atmospheric throughout the entire combined device. To achieve this aim, the sealing of the cellular wheel sluice 26 can be optimized by heating its housing.

[0212] When the tobacco initial material is introduced into the chamber 22, the material is at a pressure higher than atmospheric pressure, which can be maintained by introducing steam to compensate for the natural leakage rate (gap and leakage volume) of the cellular wheel sluice 26. The tobacco initial material is heated by the steam, and the moisture content increases. In principle, it would also be possible to operate the drying process in the chamber using supersaturated steam, but when used for fiberization, it is usually advantageous if the introduced tobacco initial material has a high moisture content.

[0213] The tobacco initial material is transported through the conditioning chamber 21 by a conveyor screw 22. Different conditions (screw pitch, rotation speed and chamber inclination) may be used for this purpose, whereby the residence time of the tobacco initial material can be set. In some embodiments, the residence time is between 2 and 10 minutes.

[0214] Water, casing and / or flavoring materials may also be added during the pressure adjustment process, after which the tobacco initial material is transferred to the pressure fiberization device 1 through the outlet 27. The process of introducing the tobacco initial material may also be facilitated if the housing is also of a hopper-type design. In some embodiments, the typical residence time of the tobacco initial material in the pressure fiberization device 1 is less than 2 minutes, in particular less than 1 minute. The tobacco material then leaves the pressure fiberization device 1 in the desired state described above.

[0215] It is contemplated that instead of a pressure adjusting screw it would also be possible to use an adjusting screw which operates at subatmospheric pressure.

[0216] In some embodiments, the pressure fiberizing device 1 comprises a single or twin axis conveyor having a shearing gap outlet for fiberizing the tobacco material. The shearing gap comprises an orifice through which the material is sheared.

[0217] Figure 5 illustrates another embodiment of a combined pressure regulation and fiberization system. The pressure regulation device 20 and the pressure fiberization device 1 are similar to those described above with reference to Figures 3 and 4, and therefore a detailed description will not be repeated below. The difference is that the conveyor screw of the regulation device 20 and the fiberization screw of the pressure fiberization device 1 are mounted on the same shaft and driven by a single motor. If the same rotation speed is used for both screws, different methods can be used to obtain different residence times in the two process steps, for example by different cross sections / volumes or by the option of discharge in the area of ​​the regulation process.

[0218] In the embodiment of Figures 4 and 5, steam and modifiers, e.g. water and casing, are introduced through appropriate inlets in the pressure regulating device 20. Corresponding inlets for water, modifiers and steam are omitted from the pressure fibreisation device 1. The flavourings and / or casing may be introduced in both pressure ranges, i.e. in one or both pressure chambers, or at atmospheric pressure, i.e. outside the chamber.

[0219] In some embodiments, the produced non-continuous tobacco material has a viscosity of between 350 and 600 kg / m 3 The "density index" of a non-continuous tobacco material can be calculated as follows:

[0220] The non-continuous tobacco material is ground in the mill for 3 seconds to reduce the fiber length. An example of a mill that may be used to grind the non-continuous tobacco material is a coffee grinder, such as a Bialetti™ Manual Coffee Grinder (European Part Number 8002617994316). However, other types of mills are also suitable for grinding the non-continuous tobacco material to reduce the fiber length.

[0221] The non-continuous tobacco material is then sorted to collect material having a particle size in the range of 0.5 mm to 1.00 mm. By way of example, the non-continuous tobacco material may be passed through a first sieve to collect non-continuous tobacco material having a particle size of 1 mm or less and reject material having a particle size greater than 1 mm. The collected non-continuous tobacco material may then be passed through a second sieve to reject material having a particle size less than 0.5 mm. Alternatively, a sieving machine or other suitable device may be used.

[0222] 50 g of the collected non-continuous tobacco material having a particle size of 0.5-1 mm is then stored for 24 hours in a climatically controlled environment at 22° C. and 60% relative humidity.

[0223] The density index is then measured using a Borgwaldt DD 60A hydrometer in the same manner as the fill value is calculated, except that a transparent disk made of acrylic glass with a diameter of 59.5 mm and a height of 15 mm is used to reset the height before the measurement. That is, the height reset is performed including the transparent disk. More specifically, a portion of the non-continuous tobacco material (30 g) is filled into the graduated cylinder of the hydrometer, and the transparent disk is placed on the non-continuous tobacco material. The graduated cylinder is lightly bounced to ensure a flat and uniform surface between the non-continuous tobacco material and the transparent disk. A measurement is then obtained in the same manner as the fill value is measured.

[0224] Density index (DI) (kg / m 3 ) is calculated according to the following formula: DI=(m / (9*π*h)*1000 DI=density index (kg / m3), M=mass of material (g), h=height (cm).

[0225] The density index (DIb) of the dry basis material can be calculated according to the following formula: DIb=DI / ((100=OV) / 100) DIb = density index of dry base material (kg / m 3 ), OV = oven volatiles (%) [determined directly after hydrometer measurement].

[0226] In some embodiments, the density index is between 350 and 600 kg / m 3 The range is.

[0227] In some embodiments, the density index of the dry basis material is between 300 and 550 kg / m 3 The range is.

[0228] It has been discovered that a lower density index for the produced non-continuous tobacco material results in less non-continuous material being extracted as winnowings, which in turn results in less overall tobacco material being extracted as winnowings at the rodmaker.

[0229] The present disclosure also relates to the manufacture of components for delivery systems, such as aerosol delivery systems.

[0230] The delivery systems described herein may be implemented as combustible aerosol delivery systems, non-combustible aerosol delivery systems, or non-aerosol delivery systems.

[0231] The method includes combining the non-continuous material with a tobacco material (e.g., cut tobacco) to form a tobacco mixture and then forming a component from the tobacco mixture. In some embodiments, for combustible products, the tobacco mixture includes at least 4.5% (by weight) of non-continuous material, preferably at least 5.5%, 6%, 6.5%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, or 20% (by weight) of non-continuous material. In some embodiments, for combustible products, such as combustible aerosol delivery systems, the tobacco mixture includes no more than 25% (by weight) of non-continuous material.

[0232] In some embodiments, for non-combustible products, such as non-combustible aerosol delivery systems, the tobacco mixture preferably comprises at least 5% (by weight) and up to 100% (by weight) of non-continuous material.

[0233] In some embodiments, a component of a non-combustion aerosol delivery system is provided, the component comprising an expanded tobacco material. The method described herein produces an expanded tobacco material, which may be produced, for example, in an aerosol generating section of an article for use in a non-combustion aerosol delivery system or a non-combustion delivery system described herein. Also provided is a non-combustion delivery system or a non-combustion aerosol delivery system comprising an expanded tobacco material, for example, a tobacco material produced by the method described herein. The non-combustion aerosol delivery system may be, for example, a hybrid system for producing an aerosol using a combination of aerosol-generating materials, one of which is an expanded tobacco material. The expanded tobacco material may also be used in aerosol-free delivery systems that deliver at least one substance, which may or may not contain nicotine, to a user orally, nasally, transdermally or in another manner that does not form an aerosol, such as, but not limited to, a lozenge, gum, patch, article including an inhalable powder, and oral tobacco, including snus or moist snuff. The expanded tobacco material may be produced by exposing the tobacco material to a pressure drop to cause flash evaporation, or alternatively or additionally, the expanded tobacco material may be produced by feeding the tobacco material through a shirring gap such that the tobacco material is defibrated by expansion.

[0234] In some embodiments, the component is for a combustible aerosol delivery system or a non-combustible aerosol delivery system. In some embodiments, the component is a tobacco rod.

[0235] The present disclosure further relates to aerosol delivery systems and components of aerosol delivery systems that include non-continuous materials manufactured in accordance with the present disclosure.

[0236] As used herein, the term "delivery system" includes a system that delivers at least one substance to a user, including the following: Combustible aerosol delivery systems, such as cigarettes, cigarillos, cigars, and pipes, or tobacco for roll-your-own or homemade cigarettes, whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smoking materials; non-combustion aerosol delivery systems that release compounds from aerosol-generating materials without burning the aerosol-generating materials, such as e-cigarettes, heated tobacco products, and hybrid systems that generate aerosols using a combination of aerosol-generating materials; A non-aerosol delivery system that delivers at least one substance, which may or may not contain nicotine, to a user orally, nasally, transdermally, or in another manner that does not form an aerosol, such as, but not limited to, oral products such as lozenges, gums, patches, articles including inhalable powders, and oral tobacco, including snus or moist snuff. is intended to include.

[0237] As used herein, the term "aerosol delivery system" is intended to encompass flammable and non-flammable aerosol delivery systems that deliver at least one substance to a user, including, but not limited to, the following: Combustible aerosol delivery systems, such as cigarettes, cigarillos, cigars, and pipes, or tobacco for roll-your-own or homemade cigarettes, whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smoking materials; Non-combustion aerosol delivery systems that release compounds from an aerosol-generating material without burning the aerosol-generating material, such as e-cigarettes, heated tobacco products, and hybrid systems that generate aerosols using a combination of aerosol-generating materials Includes.

[0238] According to this disclosure, a "combustible" aerosol delivery system is one in which an aerosol-generating component of the aerosol delivery system (or a component thereof) is burned or combusted during use to facilitate delivery of at least one substance to a user.

[0239] In some embodiments, the delivery system is a combustible aerosol delivery system, such as a system selected from the group consisting of a cigarette, a cigarillo, and a cigar.

[0240] In some embodiments, the present disclosure relates to components for use in combustible aerosol delivery systems, such as filters, filter rods, filter segments, tobacco rods, spills, aerosol modifier release components (capsules, threads, or beads), or papers (such as plug wrap, tipping paper, or cigarette paper).

[0241] According to the present disclosure, a "non-combustion" aerosol delivery system is one in which the aerosol-generating components of the aerosol delivery system (or components thereof) are not burned or incinerated to facilitate delivery of at least one substance to a user.

[0242] In some embodiments, the delivery system is a non-combustible aerosol delivery system, such as a powered non-combustible aerosol delivery system.

[0243] In some embodiments, the non-combustion aerosol delivery system is an e-cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0244] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system, an example of such a system being a tobacco heating system.

[0245] In some embodiments, the non-combustion aerosol delivery system is a hybrid system that uses a combination of aerosol-generating materials to generate an aerosol, where one or more of the aerosol-generating materials may be heated. Each aerosol-generating material may be, for example, in the form of a solid, liquid, or gel, and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, tobacco or a non-tobacco product.

[0246] Typically, a non-combustion aerosol delivery system may include a non-combustion aerosol delivery device and a consumable for use with the non-combustion aerosol delivery device.

[0247] In some embodiments, the present disclosure relates to consumables that include an aerosol-generating material and are configured for use with a non-combustion aerosol delivery device. These consumables are sometimes referred to as articles throughout this disclosure.

[0248] In some embodiments, the non-combustion aerosol delivery system, e.g., the non-combustion aerosol delivery device, can include a power source and a controller. The power source can be, for example, a power source or a heat source. In some embodiments, the heat source includes a carbon substrate that can be excited to dissipate power in the form of heat to an aerosol-generating material in proximity to the heat source or to an electrically heated material.

[0249] In some embodiments, the non-combustible aerosol delivery system can include an area for receiving a consumable, an aerosol generator, an aerosol-generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0250] In some embodiments, consumables for use with the non-combustion aerosol delivery device may include aerosol generating materials, aerosol generating material storage areas, aerosol generating material transfer components, aerosol generators, aerosol generating areas, housings, webs, filters, mouthpieces, and / or aerosol modifiers.

[0251] In some embodiments, the substance to be delivered may be an aerosol-generating material or a material not intended to be aerosolized, either of which may optionally include one or more active ingredients, one or more flavorings, one or more aerosol-forming materials, and / or one or more other functional materials.

[0252] In some embodiments, the substance to be delivered comprises an active agent.

[0253] An active substance as used herein may be a bioactive material, which is a material intended to achieve or enhance a physiological response. An active substance may be selected from, for example, dietary supplements, nootropics, psychotropic drugs. An active substance may be natural or synthetically obtained. An active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins (such as B6 or B12 or C), melatonin, cannabinoids, or components, derivatives, or combinations thereof. An active substance may include one or more components, derivatives, or extracts of tobacco, hemp, or another botanical material.

[0254] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0255] In some embodiments, the substance to be delivered comprises an active agent.

[0256] An active substance as used herein may be a bioactive material, which is a material intended to achieve or enhance a physiological response. An active substance may be selected from, for example, dietary supplements, nootropics, psychotropic drugs. An active substance may be natural or synthetically obtained. An active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins (such as B6 or B12 or C), melatonin, cannabinoids, or components, derivatives, or combinations thereof. An active substance may include one or more components, derivatives, or extracts of tobacco, hemp, or another botanical material.

[0257] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0258] As described herein, the active agent may include one or more components, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0259] As described herein, the active material may include or be derived from one or more botanical materials or their components, derivatives or extracts. As used herein, the term "botanical material" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, pods, husks, etc. Alternatively, the material may include active compounds naturally present in the botanical material, or synthetically obtained active compounds. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, chips, strips, sheets, etc. Examples of botanical substances include tobacco, eucalyptus, star anise, hemp, cocoa, hemp, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, bay leaf, licorice, matcha, yerba mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, rabe The active ingredient may be selected from the group consisting of behenyl alcohol, behenyl alcohol, laurel, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, bell pepper, mace, damiana, marjoram, olive, lemon balm, lemon basil, chives, caraway, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. The mint may be selected from the following mint varieties: Mentha arventis, Mentha cv., Mentha niliaca, Mentha piperita, Mentha piperita citrata cv., Mentha piperita cv., Mentha spicata crispa, Mentha cardifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata cv. and Mentha suaveolens.

[0260] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives or extracts thereof, and the botanical substance is tobacco.

[0261] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives or extracts thereof, and the botanical substance is clove, which contains several essential oils, such as eugenol, which is known to give clove some of its distinctive flavor and which is believed to have analgesic effects in traditional Chinese medicine.

[0262] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives or extracts thereof, and the botanical substances are selected from eucalyptus, star anise, cocoa and hemp.

[0263] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives or extracts thereof, and the botanical substances are selected from rooibos and fennel.

[0264] In some embodiments, the substance to be delivered comprises a fragrance.

[0265] As used herein, the terms "flavor" and "flavoring agent" refer to materials that can be used, where permitted by local regulations, to create a desired taste, odor, or other somatic sensation in products intended for adult consumers.These may be natural flavoring materials, botanical substances, extracts of botanical substances, synthetically derived materials, or combinations thereof (e.g., tobacco, hemp, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, peppermint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherries, berries, red berries, cranberries, peaches, apples, oranges, mangoes, clementines, lemons, limes, tropical fruits, papayas, etc.) Ya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberries, mulberry, citrus fruits, drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel quid, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, i Lang ylang, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, bay leaf, yerba mate, orange skin, rose, tea such as green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, turmeric, cilantro, myrtle, black currant, valerian, bell pepper, melon, The additives may include other additives such as sucralose, damiane, marjoram, olive, lemon balm, lemon basil, chives, ribes, verbena, tarragon, limonene, thymol, camphene), 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.These may be replicas, synthetic or natural ingredients, or blends thereof. They may be in any suitable form, for example a liquid such as an oil, a solid such as a powder, or a gas.

[0266] In some embodiments, the flavoring includes menthol, spearmint, and / or peppermint.

[0267] In some embodiments, the flavoring comprises cucumber, blueberry, citrus fruit, and / or red berry flavor components. In some embodiments, the flavoring comprises eugenol. In some embodiments, the flavoring comprises flavor components extracted from tobacco. In some embodiments, the flavoring comprises flavor components extracted from cannabis.

[0268] In some embodiments, the flavoring may include a sensory elicitor intended to achieve somatic sensations, usually chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or instead of the olfactory or gustatory nerves, and these may include agents that produce a heating, cooling, percussion pain, or numbing effect. A suitable heating agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucalyptol WS-3.

[0269] An aerosol-generating material is a material capable of generating an aerosol when excited, for example, by heating, irradiation, or in any other way. The aerosol-generating material may be in the form of a solid, liquid, or gel, which may or may not contain active substances and / or flavorings. In some embodiments, the aerosol-generating material may comprise an "amorphous solid," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material that may retain some fluid, such as a liquid, within it. In some embodiments, the aerosol-generating material may comprise, for example, about 50%, 60%, or 70% amorphous solid by weight to about 90%, 95%, or 100% amorphous solid by weight.

[0270] The aerosol-forming materials may include one or more active agents and / or flavorings, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0271] The aerosol-forming material may include one or more components capable of forming an aerosol. In some embodiments, the aerosol-forming material may include one or more of glycerin, 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 mixture, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0272] The one or more other functional materials may include one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and / or an antioxidant.

[0273] The material can be on or in a support to form a substrate. The support can be or include, for example, paper, card, paperboard, cardboard, reconstituted material, plastic material, ceramic material, composite material, glass, metal, or metal alloy. In some embodiments, the support includes a susceptor. In some embodiments, the susceptor is embedded in the material. In some alternative embodiments, the susceptor is on one or both sides of the material.

[0274] A consumable is an article that includes or consists of an aerosol-generating material, some or all of which is intended to be consumed during use by a user. A consumable may include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol-generating area, a housing, a paper roll, a mouthpiece, a filter, and / or an aerosol modifier. A consumable may also include an aerosol generator, such as a heater, that releases heat during use to cause the aerosol-generating material to generate an aerosol. A heater may include, for example, a combustible material, a material that can be heated by electrical conduction, or a susceptor.

[0275] A susceptor is a material that can be heated by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, such that penetration with a varying magnetic field causes induction of heating of the heating material. The heating material may be a magnetic material, such that penetration with a varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both conductive and magnetic, such that the susceptor is heatable by both heating mechanisms. A device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

[0276] An aerosol modifier is a substance, typically located downstream of the aerosol-generation region, configured to modify the generated aerosol, for example by changing the taste, odor, acidity, or another property of the aerosol. The aerosol modifier may be provided in an aerosol modifier-releasing component that is operable to selectively release the aerosol modifier.

[0277] The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may include, for example, one or more of a flavoring, a colorant, water, and a carbon adsorbent. The aerosol modifier may be, for example, a solid, liquid, or gel. The aerosol modifier may be in the form of a powder, a string, or granules. The aerosol modifier may be free of a filtration material.

[0278] An aerosol generator is a device configured to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to expose the aerosol-generating material to thermal energy, thereby releasing one or more volatile substances from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to generate an aerosol from the aerosol-generating material without heating. For example, the aerosol generator can be configured to expose the aerosol-generating material to one or more of vibration, pressure increase, or electrostatic energy.

[0279] In order to address various problems and advance the art, the entire contents of this disclosure, by way of example, show various embodiments in which the claimed invention can be practiced and provide for the production of superior tobacco materials. The advantages and features of the present disclosure are only of a representative sample of embodiments and are not exhaustive and / or exclusive. They are presented only for the purpose of aiding in the understanding and teaching of the claimed features. The advantages, embodiments, examples, features, characteristics, structures, and / or other aspects of the present disclosure should not be considered as limitations on the present disclosure as defined by the claims or limitations on the equivalents of the claims, and it is understood that other embodiments can be utilized and modifications can be made without departing from the scope and / or spirit of the present disclosure. Various embodiments can include, consist of, or consist essentially of various combinations of the disclosed elements, components, features, parts, steps, means, etc., as appropriate. In addition, the present disclosure also includes other inventions not claimed herein but which may be claimed in the future.

Claims

1. 1. A method for processing tobacco granules to produce a non-continuous tobacco material, comprising: Providing a pre-sized stem tobacco material having a Dp90 particle size of less than 2.5 mm and a Dp50 particle size of 0.7 mm to 1.5 mm; combining the pre-sized stem tobacco material with tobacco granules to produce a tobacco initial material; and treating the initial material by bringing the initial material to a predetermined increased moisture content, subjecting the initial material to an increased temperature, and subjecting the initial material to an increased pressure to bond the tobacco granules with the stem tobacco material; the step of processing the initial material includes transporting the initial material by a conveyor operated at a throughput of greater than 100 kg / hr; the method further comprising feeding the treated tobacco material through a shirring gap such that the treated tobacco material is defibrated by expansion; wherein the shearing gap is disposed between shearing surfaces, a rotary shearing member comprises one of the shearing surfaces, and the shearing member comprises at least 140 grooves, each of the grooves having a maximum width in a circumferential direction of the shearing member of between 0.7 mm and 1 mm.

2. 2. The method of claim 1, wherein the presized petiole material has a Dp90 particle size of less than 2.4, 2.3, 2.2, 2.1 or 2 mm.

3. 3. The method of claim 1 or 2, wherein the pre-sized petiole material has a Dp50 particle size of 0.8 mm to 1.4 mm.

4. 4. A method according to any one of claims 1 to 3, wherein the pre-sized petiole material has a Dp10 particle size of at least 100 microns, optionally at least 150, 200, 250, 300 or 350, 400 or 500 microns.

5. The method of any one of claims 1 to 4, wherein the step of preparing the pre-sized stem tobacco material comprises providing a starter stem material and reducing the particle size of the starter stem material using a hammer mill.

6. The method according to any one of claims 1 to 5, wherein the increase in temperature is obtained by applying external heat and / or is the result of applying mechanical pressure.

7. A method according to any one of the preceding claims, wherein the tobacco granules have a particle size of less than 1 mm, optionally less than 0.5 mm.

8. 8. The method of any one of claims 1 to 7, wherein the tobacco granules are mechanically bonded to the pre-sized stem tobacco material without the use of any externally applied binder.

9. The method according to any one of claims 1 to 8, wherein the material to be treated is treated by continuously transporting said material.

10. The method according to any one of claims 1 to 9, wherein the step of treating the initial material comprises transporting the initial material through a conveyor that enhances mechanical pressure.

11. The method of claim 10 , wherein the conveyor comprises an extruder.

12. 12. The method according to claim 10 or 11, wherein the conveyor is operated at a throughput of more than 110 kg / hr.

13. The method of any one of claims 1 to 12, wherein the initial material further comprises a winnowing.

14. The petiole material and / or winnowing are analyzed according to the following parameters:

14. The method of claim 13, comprising preconditioning to one or more of the following: temperature: 80-147°C; humidity: 6-14% by weight OV; and pressure (gas overpressure): 0-8 bar.

15. The petiole material and / or winnowing are analyzed according to the following parameters:

15. The method of claim 14, comprising preconditioning to one or more of the following: temperature: 100-120° C.; humidity: 8-12% by weight OV; and pressure (gas overpressure): 0-3 bar.

16. 16. The method of any one of claims 1 to 15, wherein the step of treating the initial material comprises bringing the initial material to a moisture content in the range of 10-50% by weight OV (oven volatiles).

17. A method according to any one of the preceding claims, wherein the step of treating the initial material comprises heating the initial material to a temperature in the range of 60 to 180°C.

18. A method according to any one of the preceding claims, wherein the step of treating the initial material comprises pressurising the initial material to a pressure in the range of 10 to 200 bar.

19. The method of any one of claims 1 to 18, wherein the non-continuous tobacco material is a fibrous and / or granular material.

20. 20. The method according to any one of claims 1 to 19, wherein the tobacco initial material comprises at least 30% (by weight) of tobacco granules.

21. 21. The method according to any one of claims 1 to 20, wherein the initial tobacco material comprises up to 50% (by weight) of tobacco granules.

22. 22. The method according to any one of claims 1 to 21, wherein the tobacco initial material comprises at least 5% (by weight) of tobacco winnowing.

23. 23. The method according to any one of claims 1 to 22, wherein the tobacco initial material comprises no more than 20% (by weight) of tobacco winnowing.

24. 24. The method according to any one of claims 1 to 23, wherein the initial tobacco material comprises 40% (by weight) to 60% (by weight) of pre-sized stem tobacco material or at least 45% (by weight) of pre-sized stem tobacco material.

25. 25. The method of any one of claims 1 to 24, wherein the initial tobacco material comprises up to 55% (by weight) of pre-sized stem tobacco material.

26. 26. A method according to any one of the preceding claims, wherein the tobacco granules comprise, consist or consist essentially of tobacco factory dust.

27. 27. The method of any one of claims 1 to 26, wherein the tobacco granules have a Dp50 particle size of less than 1 mm.

28. 28. A method according to any one of claims 1 to 27, comprising exposing the treated tobacco material to a pressure drop resulting in flash evaporation.

29. 29. The method of any one of claims 1 to 28, comprising feeding the treated tobacco material through a shirring gap such that the treated tobacco material is defibrated by expansion.

30. 30. The method of claim 29, wherein the shearing gap has a width in the range of 0.7 mm to 0.9 mm.

31. 31. The method of claim 29 or 30, wherein the shearing gap is disposed between shearing surfaces, and a rotating shearing member comprises one of the shearing surfaces.

32. The method of claim 31, wherein the shirring member comprises between 140 and 180 grooves.

33. 33. The method of claim 32, wherein each of the grooves has a maximum width of up to 2 mm.

34. 34. A method according to claim 32 or 33, wherein each of the grooves has a maximum width of at least 0.3 mm, optionally at least 0.5 mm or 0.7 mm.

35. A method according to any one of claims 31 to 34, comprising rotating the shearing member at an angular velocity of at least 10 rpm.

36. 36. The method of any one of the preceding claims, wherein the non-continuous tobacco material has an average fiber diameter of less than 0.9 mm.

37. The non-continuous tobacco material has a viscosity of 350 to 600 kg / m ３ The method according to any one of claims 1 to 36, having a density index in the range of

38. A method for producing a component for a delivery system comprising non-continuous tobacco material, the method comprising producing the non-continuous tobacco material by a method described in any one of claims 1 to 37.

39. The method of claim 38, wherein the component further comprises a second tobacco material.

40. 40. The method of claim 39, wherein the inclusion of the non-continuous tobacco material is configured to increase tar delivery during use of the component compared to when the component did not include the non-continuous tobacco material.

41. 41. The method of claim 40, wherein the inclusion of the non-continuous tobacco material is configured to increase tar delivery by at least 1.5%, 2% or 2.5% (by weight) for every 5% (by weight) of the non-continuous tobacco material during use of the component.

42. 42. The method of any one of claims 39 to 41, wherein the inclusion of the non-continuous tobacco material increases the delivery of nicotine during use of the component compared to when the component did not include the non-continuous tobacco material.

43. 43. The method of claim 42, wherein the inclusion of the non-continuous tobacco material is configured to increase nicotine delivery by at least 1.5% (by weight), 2% (by weight), or 2.5% (by weight) for every 5% (by weight) of the non-continuous tobacco material during use of the component.

44. 44. The method of any one of claims 39 to 43, wherein the inclusion of the non-continuous tobacco material reduces the delivery of carbon monoxide during use of the component compared to when the component did not include the non-continuous tobacco material.

45. 45. The method of any one of claims 39 to 44, wherein the inclusion of the non-continuous tobacco material reduces the ratio of carbon monoxide to tar delivery during use of the component compared to when the component did not include the non-continuous tobacco material.

46. 46. ​​The method of claim 45, wherein the inclusion of the non-continuous tobacco material is configured to reduce the carbon monoxide to tar delivery ratio during use of the component by at least 1.5%, 2% or 2.5% (by weight) for every 5% (by weight) of the non-continuous tobacco material.

47. A method as described in any one of claims 39 to 46, wherein the component comprises a tobacco rod for a combustible aerosol delivery system.

48. 48. A method according to any one of claims 39 to 47, wherein the inclusion of the non-continuous tobacco material reduces the pressure drop across the component during use of the component compared to when the component did not include the non-continuous tobacco material.

49. The method of any one of claims 39 to 48, wherein the components comprise tobacco material comprising the non-continuous tobacco material and the second tobacco material, and at least 4.5%, 5.5% or 6.5% (by weight) of the tobacco material is non-continuous tobacco material produced by the method of any one of claims 1 to 37, and optionally at least 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15% (by weight), 16%, 17%, 18%, 19% or 20% (by weight) of the tobacco material is non-continuous tobacco material produced by the method of any one of claims 1 to 37.

50. The method of any one of claims 38 to 49, wherein the component is for an aerosol delivery system.

51. The method of claim 50, wherein the component is a tobacco rod for a cigarette, cigar or cigarillo.

52. 51. The method of claim 50, wherein the component is for a non-combustion aerosol delivery system and optionally comprises tobacco material, and at least 5% (by mass) of the tobacco material is non-continuous tobacco material produced by the method of any one of claims 1 to 37.

53. The method of any one of claims 38 to 52, wherein the component is a tobacco rod.

54. A method for producing a product including a component, comprising producing the component by a method according to any one of claims 38 to 53.

55. A method of producing a smoking article including a component comprising producing the component by a method according to any one of claims 38 to 53.

56. A method of producing a smoking article comprising non-continuous tobacco material, comprising producing the non-continuous tobacco material by a method according to any one of claims 1 to 37.

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