Method for treating a tobacco material, device for treating a tobacco material, treated tobacco material and use thereof

Abstract

To provide a method of treating tobacco material.SOLUTION: The method comprises intermittently contacting a tobacco starting material with a heated surface to produce a dried treated tobacco material. Also provided is an apparatus for treating tobacco material. The invention also provides treated tobacco material that is seared and dried, and products comprising the same.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention provides a method for treating tobacco materials. The present invention also provides an apparatus for treating tobacco materials. The present invention further provides a treated tobacco material and a product containing the same.

Background Art

[0002] Various processes and apparatuses for drying tobacco materials are known. These involve techniques that utilize direct or indirect heating of the material to reduce the moisture content of the material to a desired level.

Summary of the Invention

[0003] In a first aspect of the present invention, there is provided a method for treating tobacco materials, comprising intermittently contacting a tobacco starting material with a heated surface to produce a treated tobacco material having a moisture content of 0 to about 10% oven volatile (OV).

[0004] In some embodiments, the tobacco starting material is agitated to intermittently contact the heated surface.

[0005] In some embodiments, the temperature of the heated surface is at least about 100°C to about 300°C before contacting the tobacco material. In some embodiments, the temperature of the heated surface is at least about 120°C to about 250°C before contacting the tobacco material, or at least about 150°C to about 300°C before contacting the tobacco material.

[0006] In some embodiments, the tobacco material is heated to a peak temperature of about 120°C to about 230°C by contacting the tobacco material with the heated surface.

[0007] In some embodiments, the heated surface is a heated metal surface. In some embodiments, the surface (such as a metal surface) is directly heated.

[0008] In some embodiments, the moisture content of the treated tobacco material is about 2% OV or less.

[0009] In some embodiments, the moisture content of the tobacco starting material is at least about 5% OV. In some embodiments, the moisture content of the tobacco starting material is from about 5 to about 25% OV, and optionally from about 12 to 16% OV.

[0010] In some embodiments, the tobacco material is intermittently contacted with the heating surface for at least about 1 minute to about 15 minutes. In some embodiments, the tobacco material is intermittently contacted with the heating surface for at least about 2 minutes to about 10 minutes, and optionally for at least about 2.5 minutes to about 5 minutes.

[0011] In some embodiments, at least one of water and steam is added to the tobacco material during processing to increase its moisture content. In some embodiments, at least one of water and steam is repeatedly added to the tobacco material during processing.

[0012] In some embodiments, the method of the present invention is a continuous process

[0013] In some embodiments, the tobacco material is agitated by at least one selected from the group consisting of a screw mechanism, a dual screw mechanism, an air flow, and a rotating drum.

[0014] In some embodiments, the tobacco starting material is one or more selected from the group consisting of shredded stalks, shredded laminae, laminae in leaf form, shredded laminae, stalk fibers, fine stalks, and long stalks.

[0015] In some embodiments, the sugar content of the processed tobacco is about 40% to about 95% less than the sugar content of the tobacco starting material. In some embodiments, the sugar content of the processed tobacco is about 70 to about 90% less than the sugar content of the tobacco starting material.

[0016] In some embodiments, the nicotine content of the processed tobacco material is about 10% to about 80% less than the nicotine content of the tobacco starting material. In some embodiments, the nicotine content of the processed tobacco material is about 20% to about 50% less than the nicotine content of the tobacco starting material.

[0017] In some embodiments, the ammonia content of the processed tobacco is about 30% to about 99% less than the ammonia content of the tobacco starting material. In some embodiments, the ammonia content of the processed tobacco is about 50% to about 90% less than the ammonia content of the tobacco starting material.

[0018] In some embodiments, the tobacco starting material is cut lamina, and the fill value of the processed tobacco is at least about 5% greater than the fill value of the cut lamina starting material. In some embodiments, the fill value of the processed tobacco is at least about 15% greater than the fill value of the cut lamina starting material. In some embodiments, the fill value of the processed tobacco is at least about 30% to about 50% greater than the fill value of the cut lamina starting material.

[0019] In a second aspect of the present invention, there is provided an apparatus for treating a tobacco material, the apparatus including a heated surface that intermittently contacts the tobacco material and is provided for heating and drying the tobacco material to a moisture content of 0 to about 10% oven volatile (OV).

[0020] In some embodiments, the apparatus further includes means for agitating the tobacco material. In some embodiments, the means for agitating the tobacco includes at least one selected from the group consisting of a screw mechanism, a dual screw mechanism, an air flow, and a rotating drum.

[0021] In some embodiments, the temperature of the heated surface is at least about 100°C to about 300°C before contacting the tobacco material. In some embodiments, the temperature of the heated surface is at least about 120°C to about 250°C before contacting the tobacco material, or at least about 150°C to about 300°C before contacting the tobacco material.

[0022] In some embodiments, the tobacco material is heated to a peak temperature of about 120°C to about 230°C by contacting the tobacco material with the heated surface.

[0023] In some embodiments, the heated surface is a heated metal surface.

[0024] In some embodiments, the heated surface is heated by a heating medium, which is water, oil, steam, electricity, or a combination thereof.

[0025] In a third aspect of the present invention, there is provided a processed tobacco material having a surface charred and a moisture content of 0 to about 10% oven volatile (OV).

[0026] In some embodiments, the processed tobacco material of the present invention is obtained or can be obtained by the method according to the first aspect of the present invention.

[0027] In some embodiments, the processed tobacco material of the present invention has a reduced amount of one or more of the group consisting of sugars, nicotine, and ammonia as compared to the tobacco material before being processed.

[0028] In some embodiments, the sugar content of the processed tobacco material is about 40% to about 95% or about 70% to about 90% less than the sugar content of the tobacco starting material.

[0029] In some embodiments, the nicotine content of the processed tobacco material is about 10% to about 80% or about 20% to about 50% less than the nicotine content of the tobacco material before being brought into contact with the heated surface.

[0030] In some embodiments, the ammonia content of the processed tobacco material is about 30% to about 90% or about 50% to about 90% less than the ammonia content of the tobacco material before the tobacco material is brought into contact with the heated surface.

[0031] In some embodiments, the tobacco starting material is one or more selected from the group consisting of shredded stalks, shredded laminae, laminae in leaf state, shredded laminae, stalk fibers, fine stalks, and long stalks.

[0032] In some embodiments, the tobacco starting material is cut lamina, and the fill value of the processed tobacco is at least about 5% greater than the fill value of the cut lamina starting material or at least 15% greater than the fill value of the cut lamina starting material. In some embodiments, the fill value of the processed tobacco is at least about 30% to about 50% greater than the fill value of the cut lamina starting material.

[0033] In a fourth aspect of the invention, there is provided a tobacco industry product comprising the processed tobacco material of the third aspect of the invention.

[0034] In a fifth aspect of the invention, there is provided the use of the processed tobacco material of the third aspect of the invention for manufacturing a tobacco industry product.

Brief Description of the Drawings

[0035] Embodiments of the present invention will be described by way of example only with reference to the accompanying drawings.

Figure 1

Figure 2

Modes for Carrying Out the Invention

[0036] After harvesting, the tobacco material can be processed in various ways to provide a material for consumption. One of those processes is drying. The purpose of drying is to remove moisture from the tobacco material. Other changes to the tobacco material are generally not required or observed in conventional drying processes.

[0037] Since moisture has many effects on tobacco materials, their processing characteristics, and the final products themselves, measuring the moisture content is important in tobacco industry products. When referring to "moisture", it is important to understand that a wide variety of conflicting definitions and terms are used within the tobacco industry. "Moisture" or "moisture content" is generally used to mean the water content of a material, but in the context of the tobacco industry, it is necessary to differentiate between "moisture" as water content and "moisture" as oven volatiles. Water content is defined as the proportion of water contained in the total mass of the solid substance. Volatiles are defined as the proportion of volatile components contained in the total mass of the solid substance. This includes water and all other volatile components. The dry weight is the mass remaining after the volatile substances have been driven off by heating. It is expressed as a proportion of the total mass. Oven volatiles (OV) is the mass of the volatile substances driven off.

[0038] The moisture content (oven volatiles) is measured as the loss of mass when the sample is dried in a forced-draft oven at a temperature adjusted to 110 °C ± 1 °C for 3 hours ± 0.5 minutes. After drying, the sample is cooled to room temperature in a desiccator for approximately 30 minutes to cool it.

[0039] Unless otherwise specified, when referring to moisture content in this specification, it means oven volatiles (OV).

[0040] Various drying devices are known and are usually selected according to the desired moisture content of the resulting dried tobacco and the properties of the tobacco material to be dried.

[0041] The Cased-Leaf Dryer (CLD) is a type of device that dries leaf tobacco (not shredded tobacco) to a very low final moisture content (about 4% or less). The initial moisture content of the leaf tobacco dried using such a device is usually about 28% to about 36%. The drying process involves placing the tobacco on a perforated band. The tobacco is dried by hot air passing through the holes in the band. The band is not directly heated but is indirectly heated by the hot air passing through the dryer. The tobacco remains in contact with the band during drying, and the temperature of the heated air used to dry the tobacco leaves is usually 80°C to 170°C, and in most cases 100°C to 140°C. Even when the dryer operates at 170°C, the hot air contains a lot of oxygen and the tobacco does not exceed 100°C as the tobacco ignites at "hot spots".

[0042] Other types of devices for drying tobacco are the Flash Tower Dryer and the Fluidised Bed Dryer. The drying process involves creating turbulence in the flow of tobacco by an air / steam mixture passing through the dryer. The beds of these dryers are not heated; instead, the air / steam mixture is heated. The Fluidised Bed Dryer is used to dry shredded leaf stalks that tend to have an initial moisture content in the range of 28% to 50% OV. Flash including HTD (High Temperature Dryer), HXD (High Expansion Flash Dryers) and Air Dryers Tower Dryers have no floor but rely on a heated air / steam mixture and are mainly used to dry cut tobacco stems having an initial moisture content in the range of 20% - 36% OV, and in some cases, cut tobacco stems having an initial moisture content in the range of 28% - 50% OV. The residence time of tobacco in the Flash Tower Dryer is extremely short, sometimes 2 or 3 seconds. On the other hand, tobacco may be dried for several minutes in a Fluidised Bed Dryer. The final moisture content of the processed tobacco produced by such devices is about 10% OV. In both types of these dryers, the tobacco temperature is about 50°C - 100°C.

[0043] Another conventional type of device for drying tobacco is the Drum Dryer. This type of dryer utilizes a heated metal drum and its drying process may be regarded as a combination of air drying and drying through a heating surface. The rotation of the drum rotates the tobacco, generating a certain level of turbulence between the tobacco and the air. While the metal surface is heated, it can only be heated to a temperature of about 60 - 130°C. The final moisture content of the tobacco processed using this type of device is over 10%. Typically, the moisture content of the starting material varies depending on the type of tobacco material to be dried. The initial moisture content of cut tobacco leaves is 20% - 26%, and the initial moisture content of cut tobacco stems is 28% - 50%. After a processing time of 3 - 4 minutes (for cut tobacco stems) or 4 - 7 minutes (for cut tobacco leaves) in the drum dryer, the moisture content of the processed tobacco becomes 12 - 15%.

[0044] In contrast to these conventional processes and devices, an important aspect of the method and device for processing tobacco according to the present invention includes a combination of drying the tobacco to a very low moisture content such as 0 - 10% OV and intermittently contacting the tobacco with one or more heated surfaces.

[0045] It has been discovered that exposing tobacco to a hot surface not only dries the tobacco material to extremely low moisture contents (based on oven volatiles), but in some embodiments, the methods of the present invention lead to one or more of the following desired chemical or physical changes: - Significant improvement in the sensory properties of shredded petioles; - For example, 70% to 90% sugar in the case of processed chopped petioles and processed chopped leaf blades A significant reduction in quantity, - For example, 20% to 50% of the treated cut petiole and treated cut leaf blade. A significant decrease in the amount of cotine, - For example, in the case of treated chopped petioles and treated chopped leaf blades, 50% to 90% A significant decrease in the analytical value of ammonia and - Significant increase in filling values, e.g. 15% to 50% for treated shredded petioles increase.

[0046] Treatment of tobacco material with the methods of some embodiments of the present invention results in chemical changes within the tobacco material that, at least in some embodiments, improve the organoleptic properties of the treated tobacco.

[0047] The organoleptic properties of tobacco materials are traditionally enhanced by a variety of different processes. Tobacco materials may be cured to prepare the leaf for consumption. Tobacco materials may be further processed, for example by aging or fermentation, to enhance the organoleptic properties of the tobacco. However, these steps are time consuming and can result in variable quality of the resulting tobacco material. Processing to enhance or add flavor and aroma to the tobacco material at later stages of tobacco processing can involve the addition of one or more additives to the tobacco and require additional processing steps and equipment, which can be costly and time consuming.

[0048] In this specification, the term "processed tobacco material" means tobacco that has undergone the treatment process of the present invention, and the term "unprocessed tobacco material" means tobacco that has not undergone the treatment process of the present invention (although it may have undergone other treatments).

[0049] In this specification, the term "tobacco material" includes any part such as leaves or stems and related by-products of any species of the genus Nicotiana. The tobacco material for use in the present invention is preferably from tobacco species.

[0050] In some embodiments, the tobacco starting material is one or more selected from the group consisting of cut petioles, cut leaf blades, leaf blade in leaf state, shredded leaf blades, petiole fibers, fine petioles and long petioles.

[0051] Any type, style and / or kind of tobacco may be processed. Examples of tobacco that may be used include Virginia, Burley, Comum and Maryland tobacco and and blends of these species, but are not limited thereto. Those skilled in the art recognize that processing different types, kinds and / or families results in tobacco having different sensory stimulation characteristics.

[0052] The tobacco material may be pretreated according to conventional practices.

[0053] The tobacco material to be processed may include and / or consist of cured tobacco. In this specification, the term "cured tobacco" means tobacco that has been cured but has not undergone further treatment steps to change the taste and / or aroma of the tobacco material. The cured tobacco may be blended with other types, families and / or styles. The cured tobacco does not include or consist of cut waste tobacco.

[0054] Alternatively or in addition, the tobacco material to be processed may include and / or consist of tobacco processed at the stage carried out in a Green Leaf Threshing (GLT) plant. This may include re-graded, green-leaf blended, conditioned, stem-removed or threshed (or not in the case of whole leaves), dried and / or compressed tobacco. In some embodiments, the tobacco material includes lamina tobacco material. For example, the tobacco may include from about 70% to 100% lamina. In some embodiments, the tobacco material includes 50% or less, 60% or less, 70% or less, 80% or less, 90% or less, or 95% or less lamina tobacco material. In some embodiments, the tobacco material includes 100% or less lamina tobacco material. In other words, the tobacco material may include substantially completely or completely lamina tobacco material. Alternatively or in addition, the tobacco material may include at least about 50%, at least about 60%, at least about 70%, at least about 80%, at least about 90%, or at least about 95% lamina tobacco material.

[0055] When the tobacco material includes lamina tobacco material, the lamina may be in the state of a complete leaf. In some embodiments, the tobacco material includes cured whole leaf tobacco. In some embodiments, the tobacco material substantially includes cured whole leaf tobacco. In some embodiments, the tobacco material consists essentially of cured whole leaf tobacco. In some embodiments, the tobacco material does not include shredded tobacco. In some embodiments, the tobacco is cut lamina and / or expanded tobacco (such as dry ice expanded tobacco, DIET, etc.).

[0056] Alternatively or in addition, the tobacco material may include at least about 50%, at least about 60%, at least about 70%, at least about 80%, at least about 90%, or at least about 95% lamina tobacco material.

[0057] In some embodiments, the tobacco material includes petiole tobacco material. The tobacco may include from about 90% to 100% petiole material.

[0058] In some embodiments, the tobacco material includes petiole tobacco material. The tobacco may include from about 90% to 100% petiole material.

[0059] The tobacco material may contain up to about 50%, up to about 60%, up to about 70%, up to about 80%, up to about 90% or up to 95% of petiole tobacco material. In some embodiments, the tobacco material contains up to 100% of petiole tobacco material. In other words, the tobacco material may contain substantially completely or completely petiole tobacco material. Alternatively or in addition, the tobacco material may contain at least about 50%, at least about 60%, at least about 70%, at least about 80%, at least about 90% or at least about 95% of petiole tobacco material.

[0060] In some embodiments, the tobacco material contains a blend of leaf blade and petiole.

[0061] In some embodiments, the tobacco material includes expanded tobacco such as dry ice expanded tobacco (DIET).

[0062] The tobacco is intermittently contacted with the heated surface and thus repeatedly exposed to high temperatures for short periods of time. In some embodiments, this intermittent contact may be performed by agitating the tobacco. The temperature of the heated surface, and thus the temperature to which the tobacco is exposed, is significantly higher than about 100°C and in some embodiments is at least about 150°C. Thus, intermittent contact is important to ensure that the tobacco does not burn by being continuously exposed to such a high temperature surface for a long time.

[0063] In some embodiments, the surface of the tobacco material will be burned or charred by the intermittent contact of the tobacco with the heated surface. This is the result of suddenly exposing it to high temperatures. This not only has a drying effect but also represents a different treatment of tobacco from the gentle drying processes known in the prior art.

[0064]

[0065] ​In some embodiments, the amount of oxygen around the tobacco being processed may be reduced. This has the effect of reducing the risk of "hot spots" formed as a result of exposure to the heated surface and reducing the risk of burning of the tobacco. Thus, such a reduction in the amount of oxygen allows the tobacco to be processed at a higher temperature with conventional processes and apparatus. In some embodiments, the amount of oxygen is reduced by adding steam.

[0066] While not wishing to be bound by any particular theory, the process of the present invention is presumed to be divided into two stages. In the first stage, the tobacco material is dried as a result of being exposed to heat that drives off volatile components including water during the steam distillation of a certain type of tobacco material. In the second stage, an effect referred to herein as "surface burning" occurs. It is during this second stage that major chemical changes take place within the tobacco.

[0067] It is presumed that the tobacco and the heated surface come into contact for a short time, leading to local burning of the tobacco and an increase in Maillard and caramelization reaction products, many of which are known to contribute to the desired sensory stimulation characteristics. This will be described in detail in the following examples. The Maillard reaction is a chemical reaction between amino acids and sugars, which are present in the tobacco starting material but are only slightly visible in the processed tobacco material. This is a non-enzymatic reaction that typically occurs at temperatures between 140 and 165 °C. In addition to imparting a pleasant effect on the sensory stimulation characteristics of the Maillard reaction products, this reaction is also responsible for the browning of the material. It has been observed that the tobacco processed according to an embodiment of the present invention is darker brown than the tobacco starting material.

[0068] In some embodiments, the process for treating the tobacco material of the present invention, as described herein, produces tobacco with improved flavor characteristics or improved sensory stimulation characteristics (compared to the flavor characteristics of tobacco that has not been processed or has been processed using only conventional curing processes). This means maintaining the tobacco flavor characteristics as seen after conventional curing while reducing off-notes or harshness. As used herein, the terms "improve" or "improvement" refer to flavor or In relation to sensory stimulation characteristics, it means that the taste or taste quality identified by a skilled smoker has been improved or enhanced. This may include, but is not necessarily required to, intensify the taste.

[0069] When referring to the sensory stimulation characteristics of a tobacco material in this specification, it means, for example, the sensory stimulation characteristics of the tobacco material itself when a consumer holds it in the mouth and uses it. Additionally or alternatively, it means the sensory stimulation characteristics of the smoke generated by the combustion of the tobacco material or the vapor generated by the heating of the tobacco material. In some embodiments, the processed tobacco material provides a tobacco product that includes the above tobacco material having desired sensory stimulation characteristics when used or consumed.

[0070] In some embodiments, the method of the present invention has the unexpected advantage of reducing the negative sensory effect of the stalk on the overall performance of the blend. Contributing to mouse coating, cellulose-like and "stalky" tastes is regarded as a negative aspect of the overall characteristics of the stalk.

[0071] Furthermore, the surface burning also has a physical effect on the tobacco material, and it is speculated that the individual cells of the plant material expand when the moisture inside is rapidly heated and evaporated.

[0072] In some embodiments, the temperature of the heated surface is in the range of about 100°C to about 300°C. In some embodiments, the temperature is at least about 105°C, 110°C, 115°C, 120°C, 125°C, 130°C, 135°C, 140°C, 145°C, 150°C, 155°C, 160°C, 165°C, 170°C, 175°C, 180°C, 185°C, 190°C, 195°C or at least about 200°C. In some embodiments, the temperature of the heated surface is about 295°C, 290°C, 285°C, 280°C, 275°C, 270°C, 265°C, 260°C, 255°C, 250°C, 245°C, 240°C, 235°C, 230°C, 225°C, 220°C, 215°C, 210°C, 205°C or less or about 200°C or less. In some embodiments, the temperature of the heated surface is at least about 120°C to about 250°C or at least about 150°C to about 300°C.

[0073] When referring to the temperature of the heated surface, it means the temperature before contact with the tobacco material in this specification. This is because the heated surface is cooled by contact with the tobacco material and the drying process. Therefore, the exact temperature of the heated surface during the drying process depends on how much the "drying operation" is carried out. For example, at the initial stage when water is evaporated from the tobacco, more energy is utilized, leading to the overcooling of the heated surface. Therefore, it is the temperature of the heated surface before contact with the tobacco that can be easily and accurately measured.

[0074] In some embodiments, the temperature of the heated surface is controlled to minimize changes during processing. For example, a feedback mechanism is used to ensure that the temperature is reliably maintained within an acceptable range, and the surface is heated when the temperature drops as a result of processing the tobacco material.

[0075] In some embodiments, it is suitable for the temperature of the heated surface to be adjusted according to the type of tobacco material to be processed. One reason this is suitable is that various tobacco materials have different starting moisture contents, and thus their processing involves removing different amounts of moisture and volatile components. Also, various tobacco materials have different physical properties. For example, leaves have a more fragile structure, while tobacco stalks are more woody and robust.

[0076] In some embodiments, the heated surface is a metal such as stainless steel or any other suitable steel or metal type having sufficient heat transfer properties. In other embodiments, the heated surface is formed from any material having sufficient heat transfer properties that can be heated to the temperatures used in the methods described herein. For example, a surface made of ceramic may be used.

[0077] The heated surface may be indirectly heated by a heating medium such as a heating medium selected from the group consisting of, for example, oil, water, or steam. In some embodiments, thermal oil is the preferred heating medium. Separately or in addition, the heated surface may be directly heated. In some embodiments, the heated surface is heated electrically.

[0078] In some embodiments, the temperature of the heated surface before contacting the tobacco material is in the range of about 170°C to about 190°C when processing leaf tobacco. In some embodiments, the temperature of the heated surface before contacting the tobacco material is above 200°C, optionally in the range of about 220°C to about 250°C, when processing stalk tobacco.

[0079] When the tobacco material comes into intermittent and repeated contact with the heated surface, the tobacco material is heated. If the heated surface is at a high temperature, the temperature of the tobacco will rise significantly. As a result of the processing method of the present invention in some embodiments, the temperature of the tobacco material rises to a peak temperature in the range of about 120°C to about 230°C. In some embodiments, the peak temperature of the tobacco material is at least about 125°C, 130°C, 135°C, 140°C, 145°C, 150°C, 155°C, 160°C, 165°C, 170°C, 175°C, 180°C, 185°C, 190°C, 195°C, 200°C, 205°C, 210°C, 215°C or at least about 220°C. In some embodiments, the peak temperature of the tobacco is about 225°C or less, 220°C or less, 215°C or less, 210°C or less, 195°C or less, 190°C or less, 185°C or less, 180°C or less, 175°C or less, 170°C or less, 165°C or less, 160°C or less, 155°C or less, 150°C or less, 145°C or less, 140°C or less, 135°C or less, 130°C or less or about 125°C or less. The temperature of the tobacco is measured with a suitable measuring device such as an infrared thermometer or an electrical resistance thermometer.

[0080] In some embodiments, the tobacco material is heated in an inert atmosphere.

[0081] In some embodiments, an inert gas such as nitrogen, saturated steam, carbon dioxide or a mixture thereof is added to the device to adjust the amount of oxygen and induce a desired chemical reaction during the process.

[0082] The treatment of the tobacco material of the present invention has a drying effect, and the moisture content of the tobacco material decreases. The moisture content of the treated tobacco material is from 0% to about 10% oven volatile (OV). In other words, the moisture content of the treated tobacco material does not exceed about 10% OV. In some embodiments, the moisture content of the treated tobacco material is 9.5% or less, 9% or less, 8.5% or less, 8% or less, 7.5% or less, 7% or less, 6.5% or less, 6% or less, 5.5% or less, 5% or less, 4.5% or less, 4% or less, 3.5% or less, 3% or less, 2.5% or less, 2% or less, 1.5% or less, 1% or less, or about 0.5% OV or less. In some embodiments, the moisture content of the treated tobacco material is about 2% OV or less.

[0083] In some embodiments, the moisture content of the tobacco starting material is at least about 5% OV. In some embodiments, the moisture content of the tobacco starting material is at least about 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, or at least about 24% OV. In some embodiments, the moisture content of the tobacco starting material is about 25% or less, 24% or less, 23% or less, 22% or less, 21% or less, 20% or less, 19% or less, 18% or less, 17% or less, 16% or less, 15% or less, 14% or less, 13% or less, 12% or less, 11% or less, 10% or less, 9% or less, 8% or less, 7% or less, or about 6% OV or less. In some embodiments, the moisture content of the tobacco starting material is at least about 5% to about 25% OV or at least about 5% to about 20% OV. In some embodiments, the moisture content of the tobacco starting material is at least about 12% to about 16% OV.

[0084] Thus, in some embodiments, the starting material used in the process of the present invention is a moisture content in the sense that the tobacco material is already dry. In some embodiments, the main purpose of this tobacco treatment is not to further reduce the moisture content of the tobacco starting material, but to physically and chemically change the tobacco by surface burning caused by short-time contact of the heated surface at a high temperature. In some embodiments, this effect is achieved without burning or substantially burning the tobacco as a result of contact with the heated surface.

[0085] In some embodiments, the moisture content of the tobacco material may be adjusted during processing by adding moisture. The moisture may be introduced into the tobacco during processing in the form of water or steam. This may be sprayed onto the tobacco material while it is in contact with the intermittently heated surface.

[0086] In some embodiments, the introduction of this moisture increases the moisture content of the tobacco material by 2% - 5% OV. In some embodiments, the moisture is introduced at various positions throughout the process.

[0087] Since this wetting of the tobacco occurs during processing, the moisture content decreases again because the wetted tobacco comes into contact with the heated surface. The method of the present invention may include multiple additions of moisture such that the moisture content of the tobacco material fluctuates up and down repeatedly during processing.

[0088] In some embodiments, the treatment of the present invention includes repeatedly and intermittently contacting the tobacco material with one or more heated surfaces over a treatment time of at least about 1 minute to about 15 minutes. In some embodiments, the time for intermittently contacting the tobacco with the heated surface is at least about 1 minute, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13 or at least about 14 minutes. In some embodiments, the time for intermittently contacting the tobacco with the heated surface is about 14 minutes or less, 13 minutes or less, 12 minutes or less, 11 minutes or less, 10 minutes or less, 9 minutes or less, 8 minutes or less, 7 minutes or less, 6 minutes or less, 5 minutes or less, 4 minutes or less, 3 minutes or less or about 2 minutes or less. In some embodiments, the tobacco material is contacted with the heated surface for a total of at least about 2 minutes to about 10 minutes or at least about 2.5 minutes to about 5 minutes.

[0089] The intermittent contact may include direct and continuous contact of the tobacco with the heated surface for about 5 seconds. In some embodiments, the average time of the direct and continuous contact is from about 0.1 second to about 3 seconds.

[0090] When referring to the intermittent contact of the tobacco material with the heated surface, it means that every part of the tobacco material comes into direct contact with the heated surface only temporarily. In some embodiments, this means that the tobacco material moves relative to the heated surface and does not remain stationary at a particular position in contact with the heated surface for too long and / or the same part of the tobacco material does not remain in direct contact with the heated surface for too long. Prolonging the contact time between the same part of the tobacco material and the heated surface leads to the combustion of the tobacco material, which has a harmful effect on the physical and chemical properties of the tobacco material and, for example, turns the tobacco material into a treated material that is not suitable for further use in tobacco industry products.

[0091] In some embodiments, the method of the present invention includes agitating the tobacco material when the tobacco material is being treated. In some embodiments, an apparatus is provided that includes means for agitating the tobacco material.

[0092] In some embodiments, the tobacco material is preferably agitated by tumbling the tobacco material. This may be done, for example, by grasping the tobacco to be treated, lifting it, and dropping it to cause a tumbling motion of the tobacco material.

[0093] In some embodiments, the tumbling motion of the tobacco material may be performed by a mechanism such as one that includes one or more screws. In such a configuration, the screw includes a helical surface that surrounds a rotating shaft, and this helical surface has a structure for lifting the tobacco material. When the shaft rotates, the helical surface scoops up at least a portion of the tobacco material being processed. This tobacco material is then conveyed and lifted by the rotating helical surface until the rotation of the screw drops the tobacco material from the screw (by gravity). In some embodiments, one or more screws may be arranged to move the tobacco material through the processing chamber and agitate the tobacco material. Such an arrangement enables continuous processing of the tobacco. In some embodiments, the helical surface and / or the shaft of the screw may be heated to provide a heated surface used for processing the tobacco. When two screws are used for moving the tobacco material, these screws may be arranged in parallel, in contact with and positioned to move all of the tobacco being processed. In some embodiments, the screw may include additional paddles to assist in lifting and conveying the tobacco material. These paddles may also be heated surfaces used for processing the tobacco material.

[0094] In other embodiments, the tobacco material may be agitated within a rotating drum. The interior of the drum may be a chamber in which the tobacco is processed. The tobacco is positioned inside the drum and as the drum rotates, the tobacco is picked up from the bottom of the drum and lifted. The tobacco material may be made easier to pick up by having a drum with an inner surface that can maintain contact with the tobacco material, such as a rough surface or protrusions, for example paddles that scoop up the tobacco material. As the drum rotates, the tobacco in contact with the inner surface of the drum is lifted by the rotation of the drum until it drops (due to gravity) from the wall of the drum and returns to the bottom of the drum. This causes tumbling and mixing of the tobacco material. This aids in controlling how long the irregularities on the inner surface of the drum keep the tobacco material in contact with the drum wall. The irregularities may be used so that the tobacco material does not remain in contact with the drum as it falls (slides back down the wall), in order to enhance the tumbling motion of the tobacco material. The rotational speed also affects the tumbling motion, as does the orientation of the axis of rotation. In some embodiments, the inner surface of the drum may be a heated surface used to process the tobacco. The drum may rotate about a horizontal or substantially horizontal axis. In other embodiments, rotation about an inclined axis allows the tobacco to remain in contact with the inner surface of the drum for longer and also moves the tobacco material longitudinally. The longitudinal movement of the tobacco as a result of the rotation of the drum may also or alternatively be effected by appropriately arranged and / or angled protrusions on the inner surface of the drum.

[0095] In other embodiments, the tobacco material may be agitated by an air stream. For example, the tobacco material may be lifted and moved by an air stream.

[0096] In some embodiments, the tobacco material is not agitated by the flow of air through the device. In some embodiments, the device for processing the tobacco material does not include means for sucking air through a device for agitating the tobacco material.

[0097] In some embodiments, the method of the present invention is a continuous method. For example, the tobacco starting material is continuously supplied to the apparatus, processed, and exits the apparatus as processed tobacco. In another embodiment, the method of the present invention is a batch process, in which a batch of tobacco starting material is supplied to the apparatus, processed to produce a batch of processed tobacco material, and removed before a new batch is processed.

[0098] In some embodiments, after processing, the processed tobacco may be conditioned. For example, in some embodiments, moisture may be added to the processed tobacco material. In some embodiments, this is accomplished by exposing the processed tobacco material to water and / or steam. In some embodiments, the moisture content is increased to about 10% OV or from about 10% to about 20% OV.

[0099] In some embodiments, after processing, the processed tobacco may be cooled. In some embodiments, this involves the use of a cooling belt through which ambient air or cooled air passes over a layer of the processed tobacco. In other embodiments, the tobacco material may be cooled by one or more of the steps such as allowing it to stand, passing it through a cooling cylinder, air-lifting, and cooling via a fluidized bed.

[0100] The flowchart of FIG. 1 summarizes an example of the steps for processing tobacco material. The tobacco starting material may be subjected to preliminary treatment, such as a conventional primary manufacturing (PMD) process including, if necessary, one or more of conditioning of the raw stalk, subsequent rolling, cutting, and expansion / drying and mixing. In some embodiments, the preliminary treatment of the leaf blade may include slicing thinly, conditioning, casing (if necessary), cutting, drying, cooling, and mixing.

[0101] The moisture content of the tobacco starting material is, for example, within the range of 14.5% OV. The starting material is fed to a processing apparatus that is processed by intermittent contact with the heated surface. During the processing, the tobacco material is agitated to create intermittent contact with the heated surface. The moisture content is reduced to about 0% OV by this processing. When the processing of the tobacco material by intermittent contact with the heated surface is completed, the processed tobacco material may be conditioned if necessary. In the exemplary process, this includes adding water or steam to the processed tobacco material to increase its moisture content to, for example, within the range of 14.5% OV.

[0102] The process parameters are sufficiently lenient for the processed tobacco material to maintain some or all of the physical characteristics of the tobacco material. For example, the tobacco material remains sufficiently unimpaired for subsequent processing that enables handling and / or processing for incorporation into a tobacco-containing product such as a smoking article. This allows the tobacco material to be handled by standard processing in the same manner as conventional tobacco that has not been subjected to the processes described herein.

[0103] A specific example of an apparatus suitable for implementing the embodiments of the method described herein is shown in FIG. 2. In this embodiment, the apparatus 1 includes two screws 2 of a dual screw structure. This configuration is considered such that any part of the tobacco material comes into contact with the heated surface for a time of about a few seconds as a result of the agitation or turbulence generated by the screws of this apparatus.

[0104] The tobacco material 8 is processed in an apparatus 1 that includes a conventional conveying screw 2 that includes a helical surface 3 and a shaft 4. The screw 2 moves the tobacco material through the processing chamber 7 of the apparatus 1. The screw 2 rotates, and the shaft 4 of the screw 2 is rotated by a drive mechanism 11 that includes a motor.

[0105] The tobacco starting material enters the processing chamber 7 through the tobacco inlet 5, at which time the rotating screw picks up the tobacco material, rotates it, and moves it through the processing chamber towards the tobacco outlet 6.

[0106] More specifically, the mass of the tobacco material 8 enters the processing chamber 7 through the tobacco inlet 5. When the screw 2 rotates, the tobacco material is picked up, and a part of it comes into direct contact with the spiral surface 3 and may also come into contact with the shaft 4 of the screw 2. The tobacco material is dragged along the screw 2 so that the tobacco material is conveyed and rotated within the processing chamber 7, lifted by the screw 2, and then dropped. The tobacco lifted by one or more rotating screws then falls onto the mass of the tobacco material 8 being conveyed within the chamber 7, and the mass is uniformly mixed and moved, so that different parts of the mass come into contact with the screw 2 at different times.

[0107] In the exemplary embodiment, the surfaces of the screws 2 are heated, and they intermittently come into contact with the tobacco material according to the processing of the tobacco of the present invention.

[0108] The screw 2 has a metal surface that is heated by a heating medium supplied to the apparatus 1 through the heating medium pipe 10. In the exemplary embodiment, the heating medium is heat transfer oil heated to a desired temperature.

[0109] Only a part of the tobacco material to be processed comes into direct contact with the heated surface at any given time. When the tobacco is being conveyed, the tobacco is tumbled and mixed, providing agitation and turbulence of the tobacco material and achieving the desired intermittent contact with one or more heated surfaces. The individual contact times are considered not to exceed 2 or 3 seconds at a time. The power of the tobacco flow ensures uniform processing of the entire mass of the tobacco induced by the shape of the screw.

[0110] In the illustrated apparatus, the processing chamber may be divided into different temperature zones 9. These zones represent different sections of the screw, and those sections are heated separately. Therefore, the apparatus of the present invention can be configured to have surfaces heated to various temperatures. In some embodiments, it is desirable to control the drying and surface burning stages of the treatment by exposing the tobacco to heated surfaces having different temperatures at different points during the treatment process.

[0111] The processed tobacco according to the present invention may be used in tobacco industry products. Tobacco industry products mean any item manufactured or sold in the tobacco industry, usually a) tobacco for cigarettes, cigars, cigars, pipes or hand-rolled cigarettes (regardless of whether it is based on tobacco, tobacco derivatives, expanded tobacco, reclaimed tobacco or tobacco substitutes), b) non-smoking products such as sniffing tobacco, snus, hard tobacco, etc. incorporating tobacco, tobacco derivatives, expanded tobacco, reclaimed tobacco or tobacco substitutes, and non-combustion heating (HnB) products, and c) aerosol generating devices such as inhalers, electronic cigarettes, and nicotine delivery systems for tobacco such as lozenges and gums. This example does not exclude others, but merely illustrates a series of products manufactured and sold in the tobacco industry.

[0112] The processed tobacco material may be incorporated into smoking articles. As used herein, the term "smoking article" includes smokable products such as cigarettes, cigars and cigars, and non-combustion heating products, regardless of whether they are based on tobacco, tobacco derivatives, expanded tobacco, reclaimed tobacco or tobacco substitutes.

[0113] The processed tobacco material may be used for hand-rolled cigarettes and / or pipe tobacco.

[0114] The processed tobacco material may be incorporated into "smokeless tobacco products". "Smokeless tobacco products" as used herein means any tobacco product not intended for combustion. This includes any smokeless tobacco product designed to be placed in the user's mouth for a limited time and which comes into contact with the user's saliva while in the mouth.

[0115] The processed tobacco material may be blended with one or more tobacco materials before being incorporated into smoking articles or smokeless smoking articles or used for hand-rolled cigarettes and / or pipe tobacco.

[0116] Examples The method according to the present invention was carried out on notched expanding petioles (CES) with an (initial) moisture content of 14.5% OV. A mass of tobacco particles was used as the feed material and processed by the method using the apparatus shown in Figure 2.

[0117] This treatment can be described as exposing the tobacco (petiole) particles to a hot metal surface for several seconds before the individual particles fall back onto the whole mass of the tobacco material being processed.

[0118] The residence time (and thus the processing time) of the mass of tobacco particles in the apparatus is 1 to 5 minutes. The heated metal surface is heated by a jacket that is heated in the same way as a screw that brings the surface to be heated to the desired temperature via synthetic oil.

[0119] Three different temperature sections, namely 230 °C, 240 °C and 250 °C, were tested. This means that the temperature of the heating medium (oil) used to heat the surface to be heated was set to these temperatures. This leads to different temperatures in different parts of the apparatus.

[0120] The numbers and parameters in Table 1 below reflect the individual temperatures in the middle part of the processing step when the temperature of the heating medium (oil) was set to 250 °C.

[0121]

Table 1

[0122] In these experiments, the tobacco was tested in a process with a residence time (or processing time) of about 2 to 3 minutes and a tobacco material processing rate of supplying notched petioles with a moisture content of about 14.5% OV at about 50 kg / h.

[0123] This process can be divided into two different stages. Through the first stage, the petiole particles lose their moisture. At a heating medium (oil) temperature of 250 °C, the petiole reaches a moisture content of 0% OV after about 1 minute. The second stage occurs in the remaining part of the treatment, and its effect is called "surface burning". The main changes occur through this second stage.

[0124] Table 2 compares the chemical composition of untreated tobacco with that of tobacco treated in an apparatus heated to different heating medium temperatures.

[0125]

Table 2

[0126] As can be seen from Table 2, the nicotine content of the treated tobacco decreases by more than 50% at a heating medium temperature of 250 °C, and the total of sugars and ammonia decreases by more than 80%. The increase in chloride content reflects the overall loss of organic matter, and the significant increase in the filling value indicates a change in the cell structure of the treated tobacco. These data indicate that the tobacco material has changed significantly through the treatment.

[0127] These changes can be replaced by changes in the sensory stimulation characteristics of the treated material, which are recognizable in the smoke generated when the treated tobacco is burned, for example, as a cigarette. The sensory stimulation characteristics of this smoke are expressed in very favorable terms by experienced smokers, indicating that the treatment of tobacco leads to the production of a treated material with beneficial and desirable characteristics. This is in terms of both the reduction of some undesirable tobacco components and the improvement of sensory stimulation characteristics.

[0128]

[0129] ​To address various problems and for the development of technologies, the entire present disclosure exemplarily shows various embodiments, in which the claimed invention can be practiced to provide excellent methods, devices, processed tobacco, and extracts therefrom. The advantages and features of the present disclosure are merely representative specific examples of the embodiments, neither inclusive nor exclusive. These are provided merely as an aid to the understanding and teaching of the claimed features. Of course, the advantages, embodiments, specific examples, functions, features, structures, and / or other aspects of the present disclosure should not be considered to limit the present disclosure to what is defined in the claims or to the equivalents of the claims, but rather other embodiments may be utilized and modified without departing from the scope and / or spirit of the present disclosure. The various embodiments may suitably comprise, consist of, or consist essentially of the disclosed components, elements, features, parts, steps, means, and other combinations. The present disclosure also includes other inventions that are not currently claimed but may be claimed in the future.

Claims

**Claim 1** A method for treating a tobacco material, comprising producing a treated tobacco material having a moisture content of 0 to about 10% oven volatile (OV) by intermittently contacting a tobacco starting material with a heated surface, wherein the tobacco material is directly and continuously contacted with the heated surface for about 5 seconds, exposing the tobacco material to a rapid high temperature by the contact with the heated surface to cause local burning or scorching of the tobacco material, and stirring the tobacco material by a heated screw mechanism, the heated screw mechanism including a helical surface surrounding a rotating shaft, the helical surface being configured to pick up the tobacco material. **Claim 2** The method according to claim 1, wherein the temperature of the heated surface is at least about 100°C to about 300°C before contacting the tobacco material. **Claim 3** The method according to claim 2, wherein the temperature of the heated surface is at least about 120°C to about 250°C before contacting the tobacco material, or at least about 150°C to about 300°C before contacting the tobacco material. **Claim 4** The method according to any one of claims 1 to 3, wherein the tobacco material is heated to a peak temperature of about 120°C to about 230°C by contacting the tobacco material with the heated surface. **Claim 5** The method according to any one of claims 1 to 4, wherein the heated surface is a heated metal surface. **Claim 6** The method according to any one of claims 1 to 5, wherein the moisture content of the treated tobacco material is about 2% OV or less. **Claim 7** The method according to any one of claims 1 to 6, wherein the moisture content of the tobacco starting material is at least about 5% OV. **Claim 8** The method according to claim 7, wherein the moisture content of the tobacco starting material is about 5 to about 25% OV. **Claim 9** The method according to claim 7 or 8, wherein the moisture content of the tobacco starting material is about 12 to 16% OV. **Claim 10** The method according to any one of claims 1 to 9, wherein the tobacco material is intermittently contacted with the heated surface for at least about 1 minute to about 15 minutes. **Claim 11** The method according to claim 10, wherein the tobacco material is intermittently contacted with the heated surface for at least about 2 minutes to about 10 minutes. **Claim 12** The method according to claim 11, wherein the tobacco material is intermittently contacted with the heated surface for at least about 2.5 minutes to about 5 minutes. **Claim 13** The method according to any one of claims 1 to 12, characterized in that at least one of water and steam is added to the tobacco material during processing to increase its moisture content.

14. The method according to claim 13, characterized in that at least one of water and steam is repeatedly added to the tobacco material during processing.

15. The method according to any one of claims 1 to 14, characterized in that it is a continuous process.

16. The method according to any one of claims 1 to 15, characterized in that the tobacco material is agitated by a dual screw mechanism.

17. The method according to any one of claims 1 to 16, characterized in that the tobacco starting material is one or more selected from the group consisting of cut stalks, cut laminae, laminae in leaf state, shredded laminae, stalk fibers, fine stalks and long stalks.

18. The method according to any one of claims 1 to 17, characterized in that the sugar content of the processed tobacco material is about 40% to about 95% less than the sugar content of the tobacco starting material.

19. The method according to claim 18, characterized in that the sugar content of the processed tobacco material is about 70 to about 90% less than the sugar content of the tobacco starting material.

20. The method according to any one of claims 1 to 19, characterized in that the nicotine content of the processed tobacco material is about 10% to about 80% less than the nicotine content of the tobacco starting material.

21. The method according to claim 20, characterized in that the nicotine content of the processed tobacco material is about 20% to about 50% less than the nicotine content of the tobacco starting material.

22. The method according to any one of claims 1 to 21, characterized in that the ammonia content of the processed tobacco material is about 30% to about 99% less than the ammonia content of the tobacco starting material.

23. The method according to claim 22, characterized in that the ammonia content of the processed tobacco material is about 50% to about 90% less than the ammonia content of the tobacco starting material.

24. The method according to any one of claims 1 to 23, characterized in that the tobacco starting material is cut stalks, and the filling value of the processed tobacco is at least about 5% or at least about 15% greater than the filling value of the cut stalk starting material.

25. The method according to claim 24, characterized in that the filling value of the processed tobacco is at least about 30% to about 50% greater than the filling value of the cut stalk starting material.

26. A tobacco material processing apparatus comprising a heated surface provided to intermittently contact a tobacco material and heat and dry the tobacco material to a moisture content of 0 to about 10% oven volatile (OV). The apparatus further includes a heated screw mechanism for agitating the tobacco material, the heated screw mechanism including a helical surface surrounding a rotating shaft, the helical surface being configured to pick up the tobacco material. The heated surface directly and continuously contacts the tobacco material for about 5 seconds, and the contact with the heated surface causes the tobacco material to be exposed to a sudden high temperature, resulting in local burning or charring of the tobacco material. A tobacco material processing apparatus.

27. The apparatus according to claim 26, wherein the means for agitating the tobacco material includes a dual screw mechanism.

28. The apparatus according to claim 26 or 27, wherein the temperature of the heated surface is at least about 100°C to about 300°C before contacting the tobacco material.

29. The apparatus according to claim 28, wherein the temperature of the heated surface is at least about 120°C to about 250°C before contacting the tobacco material, or at least about 150°C to about 300°C before contacting the tobacco material.

30. The apparatus according to any one of claims 26 to 29, wherein the tobacco material is heated to a peak temperature of about 120°C to about 230°C by contacting the tobacco material with the heated surface.

31. The apparatus according to any one of claims 26 to 30, wherein the heated surface is a heated metal surface.

32. The apparatus according to any one of claims 26 to 31, wherein the heated surface is heated by a heating medium, and the heating medium is water, oil, steam, electricity, or a combination thereof.

33. A processed tobacco material obtained or obtainable by the method according to any one of claims 1 to 25, having a charred surface and a moisture content of 0 to about 10% oven volatile (OV).

34. The processed tobacco material according to claim 33, wherein the processed tobacco material has a reduced amount of one or more of the group consisting of sugar content, nicotine, and ammonia as compared to the tobacco material before being processed.

35. The processed tobacco material according to claim 34, wherein the sugar content of the processed tobacco material is about 40% to about 95% or about 70% to about 90% less than the sugar content of the tobacco starting material.

36. The nicotine content of the processed tobacco material is about 10% to about 80% or about 20% to about 50% less than the nicotine content of the tobacco material before being brought into contact with the heated surface, characterized in that it is the processed tobacco material according to claim 34 or 35.

37. The ammonia content of the processed tobacco material is about 30% to about 99% or about 50% to about 90% less than the ammonia content of the tobacco material before the tobacco material comes into contact with the heated surface, characterized in that it is the processed tobacco material according to any one of claims 34 to 36.

38. The tobacco starting material is one or more selected from the group consisting of shredded leaf stalks, shredded leaf blades, leaf blades in a leaf state, shredded leaf blades, leaf stalk fibers, fine leaf stalks and long leaf stalks, characterized in that it is the processed tobacco material according to any one of claims 33 to 37.

39. The tobacco starting material is a shredded leaf stalk, and the filling value of the processed tobacco is at least about 5% or at least about 15% greater than the filling value of the shredded leaf stalk starting material or at least about 30% to about 50% greater than the filling value of the shredded leaf stalk starting material, characterized in that it is the processed tobacco material according to any one of claims 33 to 38.

40. A tobacco industry product comprising the processed tobacco material according to any one of claims 33 to 39.

41. Use of the processed tobacco material according to any one of claims 33 to 39 for manufacturing a tobacco industry product.

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