Method for producing reconstituted tobacco sheet

Abstract

Provided is a method for producing a reconstituted pressure-formed tobacco sheet. The production method has: a first step for introducing a first liquid raw material into a mixer; a second step for putting, into the mixer, a powdery raw material including at least tobacco and mixing the same with the first liquid raw material, after the first step; and a forming step for forming the raw material mixed in the second step into a pressure-formed sheet.

Description

Method for producing reconstituted tobacco sheet

[0001] The present invention relates to a method for producing a reconstituted tobacco sheet.

[0002] Conventionally, known methods for producing reconstituted tobacco sheets include the rolling method, the casting (slurry) method, and the paper-making method. These methods are selected depending on the moisture content of the reconstituted tobacco raw material. Furthermore, each of these methods is realized using a different reconstituted tobacco sheet production apparatus.

[0003] The rolling method is known to be particularly suitable for reconstituted tobacco raw materials containing 50% or less moisture by volume. In the rolling method, a kneaded product of the reconstituted tobacco raw material is rolled and molded with rotating rollers to adjust the thickness, and then dried in a separately provided dryer.

[0004] The cast (slurry) method is known to be particularly suitable for reconstituted tobacco material containing 50% or more by volume of moisture. In the cast (slurry) method, a fluid of reconstituted tobacco material is continuously spread on a rotating drum or belt conveyor, and is then leveled to a desired thickness with a member called a blade. The reconstituted tobacco material is then peeled off from the rotating drum or belt conveyor and dried in a separately provided dryer.

[0005] The papermaking method is known to be particularly suitable for reconstituted tobacco material containing 80% or more by volume of moisture. In the papermaking method, a fluid of the reconstituted tobacco material is continuously spread on a liquid-permeable belt conveyor, and after the moisture is removed and the reconstituted tobacco material is made to a desired thickness by a compression roller, it is dried in a separately provided dryer.

[0006] In contrast to these manufacturing methods, which are selected depending on the moisture content, there is known a manufacturing device and method for reconstituted tobacco sheets that can obtain reconstituted tobacco sheets of uniform thickness through a simple manufacturing process, regardless of the moisture content contained in the reconstituted tobacco raw material (see Patent Document 1).

[0007] International Publication No. 2022 / 019027

[0008] When pressure-molding a reconstituted tobacco sheet using the method disclosed in Patent Document 1 or a rolling method, no consideration is given to the method for producing reconstituted pressure-molded tobacco raw material.

[0009] One object of the present invention is to provide a novel method for producing reconstituted pressure-formed tobacco sheets.

[0010] According to a first aspect, there is provided a method for producing a reconstituted pressure-formed tobacco sheet, the method comprising: a first step of mixing two or more powder raw materials, including at least tobacco, in a mixer; a second step of, after the first step, adding a first liquid raw material to the mixer and mixing it with the two or more powder raw materials; and a forming step of forming the raw materials mixed in the second step into a pressure-formed sheet.

[0011] According to the first aspect, two or more types of powdered raw materials are mixed in the first step before the powdered raw material and the first liquid raw material are mixed, so that the two or more types of powdered raw materials can be mixed sufficiently.

[0012] The two or more powder ingredients may include tobacco, a binder, and an additive.

[0013] In this case, by mixing the powdered raw material with the first liquid raw material, a tobacco raw material with increased viscosity due to the binder can be produced. The additive may also include, for example, one or more selected from the group consisting of pulp, cellulose (such as crystallized cellulose or cellulose powder), calcium carbonate, menthol, and powdered flavoring. The inclusion of an additive in the powdered raw material can increase the strength of the tobacco sheet and impart flavor.

[0014] The first liquid source may include an aerosol source, water, and an additive.

[0015] In this case, by mixing the powder raw material with the first liquid raw material, a tobacco raw material with an increased aerosol generation rate can be produced. The aerosol source may include, for example, one or more selected from the group consisting of glycerin and propylene glycol. Furthermore, the additive may include, for example, a liquid flavoring. By including the liquid flavoring in the liquid raw material, a flavor can be imparted to the tobacco sheet.

[0016] The second step may include placing the first liquid raw material, which is formed by pre-mixing the aerosol source, the water, and the additive, into the mixer.

[0017] In this case, the aerosol source, water, and additives contained in the first liquid raw material are mixed in advance, so that the powder raw material and the first liquid raw material can be mixed more uniformly.

[0018] The above-mentioned manufacturing method may include the steps of: supplying the raw materials mixed in the second step to an extruder; and further adding a second liquid raw material to the raw materials supplied to the extruder.

[0019] In order to extrude a raw material using an extruder, the raw material must have moisture suitable for the extrusion process. On the other hand, if the moisture content of the raw material is low enough to be extruded using an extruder, the raw material will be highly viscous, making it difficult to handle the raw material outside the extruder. Therefore, when a second liquid raw material is added to the raw material in the extruder, the moisture content of the raw material can be adjusted in the extruder, thereby reducing the amount of the first liquid raw material to be mixed in the mixer. As a result, the raw material can be prevented from becoming too viscous in the mixer, making it easier to handle the raw material when feeding it from the mixer to the extruder.

[0020] The second liquid raw material may contain water.

[0021] In this case, the amount of the first liquid raw material mixed in the mixer can be reduced. As a result, the raw material can be prevented from becoming sticky in the mixer, making it easier to handle the raw material when feeding it from the mixer to the extruder. The second liquid raw material may include one or more selected from the group consisting of water, glycerin, propylene glycol, a binder solution, and a liquid flavoring.

[0022] The molding step may include a step of extruding the raw material mixed in the second step into a die using an extruder, and a step of extruding the raw material from the die into a sheet shape.

[0023] The molding step may include a step of extruding the raw material mixed in the second step using an extruder, and a step of molding the raw material extruded from the extruder into a sheet using at least a pair of rolling rollers facing each other in a vertical direction.

[0024] The forming step may include a step of extruding the raw material mixed in the second step using an extruder, and a step of passing the raw material extruded from the extruder between two or more rolling rollers horizontally adjacent to each other to form the raw material into a sheet.

[0025] According to a second aspect, there is provided a method for producing a reconstituted pressure-formed tobacco sheet, comprising: a first step of feeding a first liquid raw material into a mixer; a second step of feeding a powder raw material containing at least tobacco into the mixer and mixing it with the first liquid raw material; and a forming step of forming the raw material mixed in the second step into a pressure-formed sheet.

[0026] According to the second aspect, since the powdered raw material is mixed with the first liquid raw material, it is possible to prevent the powdered raw material from forming lumps, and it is possible to mix the raw materials more uniformly.

[0027] The powder ingredients may include tobacco, a binder, and additives.

[0028] In this case, by mixing the powdered raw material with the first liquid raw material, a tobacco raw material with increased viscosity due to the binder can be produced. The additive may also include, for example, one or more selected from the group consisting of pulp, cellulose (such as crystallized cellulose or cellulose powder), calcium carbonate, menthol, and powdered flavoring. The inclusion of an additive in the powdered raw material can increase the strength of the tobacco sheet and impart flavor.

[0029] The second step may include separately placing the tobacco, the binder, and the additive in the mixer and mixing them with the first liquid raw material.

[0030] In this case, since each powder raw material is mixed with the first liquid raw material separately, it is possible to further prevent the powder raw materials from forming lumps, and it is possible to mix the raw materials more uniformly.

[0031] The first liquid source may include an aerosol source, water, and an additive.

[0032] In this case, by mixing the powder raw material with the first liquid raw material, a tobacco raw material with an increased aerosol generation rate can be produced. The aerosol source may include, for example, one or more selected from the group consisting of glycerin and propylene glycol. Furthermore, the additive may include, for example, a liquid flavoring. By including the liquid flavoring in the liquid raw material, a flavor can be imparted to the tobacco sheet.

[0033] The above-mentioned manufacturing method may include the steps of: supplying the raw materials mixed in the second step to an extruder; and further adding a second liquid raw material to the raw materials supplied to the extruder.

[0034] In order to extrude a raw material using an extruder, the raw material must have moisture suitable for the extrusion process. On the other hand, if the moisture content of the raw material is low enough to be extruded using an extruder, the raw material will be highly viscous, making it difficult to handle the raw material outside the extruder. Therefore, when a second liquid raw material is added to the raw material in the extruder, the moisture content of the raw material can be adjusted in the extruder, thereby reducing the amount of the first liquid raw material to be mixed in the mixer. As a result, the raw material can be prevented from becoming too viscous in the mixer, making it easier to handle the raw material when feeding it from the mixer to the extruder.

[0035] The second liquid raw material may contain water.

[0036] In this case, the amount of the first liquid raw material mixed in the mixer can be reduced. As a result, the raw material can be prevented from becoming sticky in the mixer, making it easier to handle the raw material when feeding it from the mixer to the extruder. The second liquid raw material may include one or more selected from the group consisting of water, glycerin, propylene glycol, a binder solution, and a liquid flavoring.

[0037] The molding step may include a step of extruding the raw material mixed in the second step into a die using an extruder, and a step of extruding the raw material from the die into a sheet shape.

[0038] The molding step may include a step of extruding the raw material mixed in the second step using an extruder, and a step of molding the raw material extruded from the extruder into a sheet using at least a pair of rolling rollers facing each other in a vertical direction.

[0039] The forming step may include a step of extruding the raw material mixed in the second step using an extruder, and a step of passing the raw material extruded from the extruder between two or more rolling rollers horizontally adjacent to each other to form the raw material into a sheet.

[0040] According to a third aspect, there is provided a method for producing a reconstituted pressure-formed tobacco sheet, comprising: a first step of mixing water and a binder in a mixer to swell the binder; a second step of, after the first step, adding a first liquid raw material and a powder raw material containing at least tobacco to the mixer and mixing them with the swelled binder; and a forming step of forming the raw materials mixed in the second step into a pressure-formed sheet.

[0041] According to the third aspect, the binder is mixed with water in advance to swell and develop its binding function, and then mixed with the first liquid raw material and the powdered raw material. This increases the viscosity of the raw materials. As a result, the raw materials are easier to handle and easier to extrude using an extruder. Furthermore, the increased viscosity of the raw materials improves the strength of the tobacco sheet. In this specification, the binder may be one or more binders selected from the group consisting of tamarind seed gum, guar gum, locust bean gum, xanthan gum, glucomannan, native gellan gum, gum arabic, shellac, lecithin, gluten, CMC, HPC-L, HPC-H, pullulan, sorbitol, guar gum, pregelatinized waxy corn starch, glycerin gum, hydroxypropyl starch, shellac, hydroxypropyl potato starch, and phosphate-crosslinked tapioca starch.

[0042] The powder raw material may include tobacco and additives.

[0043] In this case, by mixing the powdered raw material with the first liquid raw material, a tobacco raw material with increased viscosity due to the binder can be produced. The additive may also include, for example, one or more selected from the group consisting of pulp, cellulose (such as crystallized cellulose or cellulose powder), calcium carbonate, menthol, and powdered flavoring. The inclusion of an additive in the powdered raw material can increase the strength of the tobacco sheet and impart flavor.

[0044] The second step may include placing the tobacco and the additive separately in a mixer and mixing them with the swollen binder.

[0045] In this case, each powdered raw material is mixed separately with the swollen binder, so that the powdered raw materials can be further prevented from forming lumps, and the raw materials can be mixed more uniformly.

[0046] The first liquid source may include an aerosol source and an additive.

[0047] In this case, by mixing the swollen binder, the powdered raw material, and the first liquid raw material, a tobacco raw material with an increased aerosol generation rate can be produced. The aerosol source may include, for example, one or more selected from the group consisting of glycerin and propylene glycol. The additive may also include, for example, a liquid flavoring. The inclusion of the liquid flavoring in the liquid raw material can impart a flavor to the tobacco sheet. The first liquid raw material may further include water.

[0048] The second step may include separately placing the first liquid raw material and the powder raw material in a mixer and mixing them with the swollen binder.

[0049] In this case, the first liquid raw material and the powder raw material are mixed separately, so that the raw materials can be mixed more uniformly.

[0050] The second step may include placing the first liquid raw material in a mixer before the powder raw material, and mixing the first liquid raw material with the swollen binder.

[0051] In this case, the powdered raw material is added to and mixed with the swollen binder and liquid raw material, so that the powdered raw material can be prevented from forming lumps, and the raw materials can be mixed more uniformly.

[0052] The above-mentioned manufacturing method may include the steps of: supplying the raw materials mixed in the second step to an extruder; and further adding a second liquid raw material to the raw materials supplied to the extruder.

[0053] In order to extrude a raw material using an extruder, the raw material must have moisture suitable for the extrusion process. On the other hand, if the moisture content of the raw material is low enough to be extruded using an extruder, the raw material will be highly viscous, making it difficult to handle the raw material outside the extruder. Therefore, when a second liquid raw material is added to the raw material in the extruder, the moisture content of the raw material can be adjusted in the extruder, thereby reducing the amount of the first liquid raw material to be mixed in the mixer. As a result, the raw material can be prevented from becoming too viscous in the mixer, making it easier to handle the raw material when feeding it from the mixer to the extruder.

[0054] The second liquid raw material may contain water.

[0055] In this case, the amount of the first liquid raw material mixed in the mixer can be reduced. As a result, the raw material can be prevented from becoming sticky in the mixer, making it easier to handle the raw material when feeding it from the mixer to the extruder. The second liquid raw material may include one or more selected from the group consisting of water, glycerin, propylene glycol, a binder solution, and a liquid flavoring.

[0056] The molding step may include a step of extruding the raw material mixed in the second step into a die using an extruder, and a step of extruding the raw material from the die into a sheet shape.

[0057] The molding step may include a step of extruding the raw material mixed in the second step using an extruder, and a step of molding the raw material extruded from the extruder into a sheet using at least a pair of rolling rollers facing each other in a vertical direction.

[0058] The forming step may include a step of extruding the raw material mixed in the second step using an extruder, and a step of passing the raw material extruded from the extruder between two or more rolling rollers horizontally adjacent to each other to form the raw material into a sheet.

[0059] According to a fourth aspect, there is provided a method for producing a reconstituted pressure-formed tobacco sheet, comprising a mixing step of mixing a powder raw material containing at least tobacco and a first liquid raw material in a mixer, a step of feeding the raw materials mixed in the mixing step into an extruder, a step of adding a second liquid raw material to the raw material fed to the extruder, and a forming step of forming the raw materials extruded from the extruder into a pressure-formed sheet.

[0060] In order to extrude a raw material using an extruder, the raw material must have moisture suitable for the extrusion process. On the other hand, if the moisture content of the raw material is low enough to be extruded using an extruder, the raw material will be highly viscous, making it difficult to handle the raw material outside the extruder. Therefore, according to the fourth aspect, the moisture content of the raw material can be adjusted in the extruder, thereby reducing the amount of the first liquid raw material to be mixed in the mixer. As a result, the raw material can be prevented from becoming too viscous in the mixer, making it easier to handle the raw material when feeding it from the mixer to the extruder.

[0061] The second liquid raw material may contain water.

[0062] In this case, the amount of the first liquid raw material mixed in the mixer can be reduced. As a result, the raw material can be prevented from becoming sticky in the mixer, making it easier to handle the raw material when feeding it from the mixer to the extruder. The second liquid raw material may include one or more selected from the group consisting of water, glycerin, propylene glycol, a binder solution, and a liquid flavoring.

[0063] The mixing step may include a first step of putting two or more powdered raw materials into a mixer and mixing them, and a second step of, after the first step, putting a first liquid raw material into the mixer and mixing it with the powdered raw material.

[0064] In this case, since two or more types of powdered raw materials are mixed in the first step before the powdered raw materials are mixed with the first liquid raw material, the powdered raw materials can be mixed sufficiently.

[0065] The second step may include placing the first liquid raw material, which is formed by pre-mixing an aerosol source, water, and an additive, into the mixer.

[0066] In this case, the aerosol source, water, and additives contained in the first liquid raw material are mixed in advance, so that the powder raw material and the first liquid raw material can be mixed more uniformly.

[0067] The mixing step may include a first step of putting a first liquid raw material into a mixer, and a second step of, after the first step, putting a powder raw material into the mixer and mixing it with the first liquid raw material.

[0068] In this case, since the powdered raw material is mixed with the first liquid raw material, it is possible to prevent the powdered raw material from forming lumps, and it is possible to mix the raw materials more uniformly.

[0069] The second step may include placing the tobacco, binder, and additives separately in a mixer and mixing them with the first liquid raw material.

[0070] In this case, since each powder raw material is mixed with the first liquid raw material separately, it is possible to further prevent the powder raw materials from forming lumps, and it is possible to mix the raw materials more uniformly.

[0071] The mixing step may include a first step of putting water and a binder into a mixer and mixing them to swell the binder, and a second step of, after the first step, putting a first liquid raw material and a powder raw material into the mixer and mixing them with the swollen binder.

[0072] In this case, the binder is mixed with water in advance to swell and exert its binding function, and then mixed with the first liquid raw material and the powder raw material, thereby increasing the viscosity of the raw material. As a result, the raw material is easier to extrude using an extruder. Furthermore, the increased viscosity of the raw material can improve the strength of the tobacco sheet.

[0073] The second step may include placing the tobacco and additives separately in a mixer and mixing them with the swollen binder.

[0074] In this case, each powdered raw material is mixed separately with the swollen binder, so that the powdered raw materials can be further prevented from forming lumps, and the raw materials can be mixed more uniformly.

[0075] The second step may include separately placing the first liquid raw material and the powder raw material in a mixer and mixing them with the swollen binder.

[0076] In this case, the first liquid raw material and the powder raw material are mixed separately, so that the raw materials can be mixed more uniformly.

[0077] The second step may include placing the first liquid raw material in a mixer before the powder raw material, and mixing the first liquid raw material with the swollen binder.

[0078] In this case, the powdered raw material is added to and mixed with the swollen binder and the first liquid raw material, so that the powdered raw material can be prevented from forming lumps, and the raw materials can be mixed more uniformly.

[0079] The molding step may include a step of extruding the raw material into a die by the extruder, and a step of extruding the raw material from the die into a sheet shape.

[0080] The forming step may include a step of extruding the raw material by the extruder, and a step of forming the raw material extruded from the extruder into a sheet by at least a pair of rolling rollers facing each other in a vertical direction.

[0081] The forming step may include a step of extruding the raw material by the extruder, and a step of passing the raw material extruded from the extruder between two or more rolling rollers adjacent in the horizontal direction to form the raw material into a sheet.

[0082] Fig. 1 is a schematic diagram of a manufacturing system for reconstituted pressure-formed tobacco sheets; Fig. 2 is a flowchart of a manufacturing method for reconstituted pressure-formed tobacco sheets in a mixer, extruder, and die according to a first embodiment; Fig. 3 is a flowchart of a manufacturing method for reconstituted pressure-formed tobacco sheets in a mixer, extruder, and die according to a second embodiment; Fig. 4 is a flowchart of a manufacturing method for reconstituted pressure-formed tobacco sheets in a mixer, extruder, and die according to a third embodiment; and Fig. 5 is a flowchart of a manufacturing method for reconstituted pressure-formed tobacco sheets in a mixer, extruder, and die according to a fourth embodiment.

[0083] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. In the drawings described below, identical or corresponding components are designated by the same reference numerals, and redundant description will be omitted.

[0084] Fig. 1 is a schematic diagram of a manufacturing system for reconstituted pressure-formed tobacco sheets. As shown in Fig. 1, the manufacturing system 100 for reconstituted pressure-formed tobacco sheets includes a first pulverizer 10, a second pulverizer 20, a classifier 30, a mixer 40, an extruder 50, a die 60, a take-up machine 70, and a dryer 80. In this manufacturing system 100, tobacco is first pulverized to a predetermined particle size in the first pulverizer 10. The pulverized tobacco (tobacco particles) are then pulverized to smaller particle sizes in the second pulverizer 20. The tobacco pulverized in the second pulverizer 20 is classified in the classifier 30. The tobacco rejected in the classifier 30 is pulverized again in the first pulverizer 10 and the second pulverizer 20. The tobacco classified in the classifier 30 is mixed with, for example, additives in the mixer 40 to produce a raw material for reconstituted pressure-formed tobacco sheets.

[0085] The raw material is supplied to an extruder 50, which extrudes it into a die 60. The die 60 extrudes the raw material into a sheet. The sheet-like raw material discharged from the die 60 is taken up by a take-up machine 70 and dried in a subsequent dryer 80. In this way, a reconstituted pressure-molded tobacco sheet can be produced.

[0086] 2 is a flowchart of a method for producing a reconstituted pressure-formed tobacco sheet according to the first embodiment, using a mixer 40, an extruder 50, and a die 60. In the method for producing a reconstituted pressure-formed tobacco sheet according to the first embodiment, first, two or more powdery raw materials containing at least tobacco are placed in the mixer 40 and mixed (first process: step S201). This tobacco may be tobacco leaves of any shape, but is preferably tobacco particles that have been classified by the classifier 30 shown in FIG. 1.

[0087] Subsequently, after the first step, the first liquid raw material is placed in a mixer 40 and mixed with two or more powder raw materials (second step: step S202). This produces the raw material for a reconstituted pressure-formed tobacco sheet. The raw material mixed in the second step is formed into a pressure-formed sheet (forming step). Specifically, the raw material mixed in the second step is supplied to an extruder 50 (step S203). This raw material may be highly sticky, so it may be supplied to the extruder 50 by a conveying device such as a belt conveyor.

[0088] The raw material supplied to the extruder 50 is extruded into a sheet by the extruder 50. According to the manufacturing method shown in Fig. 2, two or more types of powdered raw materials are mixed in the first process (step S201) before the powdered raw material and the first liquid raw material are mixed, so that the two or more types of powdered raw materials can be sufficiently mixed. Specifically, the raw material supplied to the extruder 50 is extruded into the die 60 by the extruder 50 (step S205), and the raw material is extruded from the die 60 into a sheet (step S206).

[0089] As shown in FIG. 2 , a second liquid raw material may be added to the raw material supplied to the extruder 50 (step S204). To extrude a raw material using the extruder 50, the raw material must have moisture suitable for the extrusion process. On the other hand, if the moisture content of the raw material is low enough to be extruded using the extruder 50, the raw material will be highly viscous, making it difficult to handle the raw material outside the extruder 50 (e.g., transporting the raw material from the mixer 40 to the extruder 50). Therefore, when the second liquid raw material is added to the raw material in the extruder 50, the moisture content of the raw material can be adjusted in the extruder 50, thereby reducing the amount of the first liquid raw material to be mixed in the mixer 40. As a result, the raw material can be prevented from becoming too viscous in the mixer 40, making it easier to handle the raw material when it is supplied from the mixer 40 to the extruder 50.

[0090] This second liquid ingredient may contain water. In this case, the amount of the first liquid ingredient mixed in the mixer 40 can be reduced. As a result, the ingredients in the mixer 40 can be prevented from becoming too viscous, making it easier to handle the ingredients when supplying them from the mixer 40 to the extruder 50. The second liquid ingredient may contain one or more ingredients selected from the group consisting of water, glycerin, propylene glycol, a binder solution, and a liquid flavoring.

[0091] In the manufacturing method shown in Figure 2, the two or more powdery raw materials preferably include tobacco, a binder, and an additive. In this case, by mixing the two or more powdery raw materials with the first liquid raw material in step S202, a tobacco raw material with increased viscosity due to the binder can be manufactured. The additive may also include, for example, one or more selected from the group consisting of pulp, cellulose (such as crystallized cellulose or cellulose powder), calcium carbonate, menthol, and powdered flavoring. The inclusion of an additive in the powdery raw material can increase the strength of the tobacco sheet and impart flavor.

[0092] In the manufacturing method shown in Figure 2, the first liquid raw material preferably contains an aerosol source, water, and an additive. In this case, by mixing two or more types of powder raw material with the first liquid raw material in step S202, a tobacco raw material with an increased aerosol generation rate can be manufactured. The aerosol source may include, for example, one or more selected from the group consisting of glycerin and propylene glycol. Furthermore, the additive may include, for example, a liquid flavoring. By including a liquid flavoring in the liquid raw material, a flavor can be imparted to the tobacco sheet.

[0093] Specifically, in the second process (step S202), a first liquid raw material formed by pre-mixing an aerosol source, water, and additives may be placed in the mixer 40. In this case, the aerosol source, water, and additives contained in the first liquid raw material are pre-mixed, so that the powder raw material and the first liquid raw material can be mixed more uniformly.

[0094] The manufacturing method shown in FIG. 2 may include, instead of steps S205 and S206, a step of extruding the raw materials mixed in the second step (step S202) using an extruder 50 and a step of forming the raw materials extruded from the extruder 50 into a sheet using at least one pair of rolling rollers facing each other in the vertical direction. More specifically, the raw materials may be formed into a sheet in stages using three sets of rolling rollers (i.e., six rolling rollers). Furthermore, the manufacturing method shown in FIG. 2 may include, instead of steps S205 and S206, a step of extruding the raw materials mixed in the second step (step S202) using an extruder 50 and a step of passing the raw materials extruded from the extruder 50 between two or more horizontally adjacent rolling rollers to form the raw materials into a sheet. More specifically, the raw materials may be passed between four horizontally adjacent rolling rollers to form the raw materials into a sheet in stages.

[0095] 3 is a flowchart of a method for producing a reconstituted pressure-formed tobacco sheet in a mixer 40, an extruder 50, and a die 60 according to a second embodiment. In the method for producing a reconstituted pressure-formed tobacco sheet according to the second embodiment, a first liquid raw material is first placed in the mixer 40 (first step: step S301). Subsequently, after the first step, a powder raw material containing at least tobacco is placed in the mixer 40 and mixed with the first liquid raw material (second step: step S302). This produces a raw material for a reconstituted pressure-formed tobacco sheet. The tobacco may be tobacco leaves of any shape, but is preferably tobacco particles classified by the classifier 30 shown in FIG. 1.

[0096] The raw materials mixed in the second step are formed into a pressure-molded sheet (molding step). Specifically, the raw materials mixed in the second step are supplied to the extruder 50 (step S303). Because this raw material may be highly viscous, it may be supplied to the extruder 50 by a conveying device such as a belt conveyor. The raw materials supplied to the extruder 50 are extruded into a sheet by the extruder 50. According to the manufacturing method shown in FIG. 3, the powdered raw materials are mixed with the first liquid raw material, which prevents the powdered raw materials from forming lumps and allows the raw materials to be mixed more uniformly. Specifically, the raw materials supplied to the extruder 50 are extruded into the die 60 by the extruder 50 (step S305), and the raw materials are extruded into a sheet from the die 60 (step S306).

[0097] As shown in FIG. 3 , a second liquid raw material may be added to the raw material supplied to the extruder 50 (step S304). To extrude a raw material using the extruder 50, the raw material must have moisture suitable for the extrusion process. On the other hand, if the moisture content of the raw material is low enough to be extruded using the extruder 50, the raw material will be highly viscous, making it difficult to handle the raw material outside the extruder 50 (e.g., transporting the raw material from the mixer 40 to the extruder 50). Therefore, when the second liquid raw material is added to the raw material in the extruder 50, the moisture content of the raw material can be adjusted in the extruder 50, thereby reducing the amount of the first liquid raw material to be mixed in the mixer 40. As a result, the raw material can be prevented from becoming too viscous in the mixer 40, making it easier to handle the raw material when it is supplied from the mixer 40 to the extruder 50.

[0098] This second liquid ingredient may contain water. In this case, the amount of the first liquid ingredient mixed in the mixer 40 can be reduced. As a result, the ingredients in the mixer 40 can be prevented from becoming too viscous, making it easier to handle the ingredients when supplying them from the mixer 40 to the extruder 50. The second liquid ingredient may contain one or more ingredients selected from the group consisting of water, glycerin, propylene glycol, a binder solution, and a liquid flavoring.

[0099] In the manufacturing method shown in Figure 3, the powdered raw material preferably contains tobacco, a binder, and an additive. In this case, by mixing the powdered raw material with the first liquid raw material in step S302, a tobacco raw material with increased viscosity due to the binder can be produced. The additive may also include, for example, one or more selected from the group consisting of pulp, cellulose (such as crystallized cellulose or cellulose powder), calcium carbonate, menthol, and powdered flavoring. The inclusion of an additive in the powdered raw material can increase the strength of the tobacco sheet and impart flavor.

[0100] In the second process (step S302), the tobacco, binder, and additives may be placed separately in the mixer 40 and mixed with the first liquid raw material. In this case, each powder raw material is mixed separately with the first liquid raw material, which further prevents the powder raw materials from forming lumps, allowing the raw materials to be mixed more uniformly.

[0101] In the manufacturing method shown in Figure 3, the first liquid raw material preferably contains an aerosol source, water, and an additive. In this case, by mixing the powder raw material and the first liquid raw material in step S302, a tobacco raw material with an increased aerosol generation rate can be manufactured. The aerosol source may include, for example, one or more selected from the group consisting of glycerin and propylene glycol. Furthermore, the additive may include, for example, a liquid flavoring. By including the liquid flavoring in the liquid raw material, a flavor can be imparted to the tobacco sheet.

[0102] The manufacturing method shown in FIG. 3 may include, instead of steps S305 and S306, a step of extruding the raw materials mixed in the second step (step S302) using an extruder 50 and a step of forming the raw materials extruded from the extruder 50 into a sheet using at least one pair of rolling rollers facing each other in the vertical direction. More specifically, the raw materials may be formed into a sheet in stages using three sets of rolling rollers (i.e., six rolling rollers). Furthermore, the manufacturing method shown in FIG. 3 may include, instead of steps S305 and S306, a step of extruding the raw materials mixed in the second step (step S302) using an extruder 50 and a step of passing the raw materials extruded from the extruder 50 between two or more horizontally adjacent rolling rollers to form the raw materials into a sheet. More specifically, the raw materials may be passed between four horizontally adjacent rolling rollers to form the raw materials into a sheet in stages.

[0103] 4 is a flowchart of a method for producing a reconstituted pressure-formed tobacco sheet in a mixer 40, an extruder 50, and a die 60 according to a third embodiment. In the method for producing a reconstituted pressure-formed tobacco sheet according to the third embodiment, water and a binder are first mixed in the mixer 40 to swell the binder (first step: step S401). Subsequently, after the first step, a first liquid raw material and a powder raw material containing at least tobacco are mixed with the swelled binder in the mixer 40 (second step: step S402). This produces a raw material for a reconstituted pressure-formed tobacco sheet. The tobacco may be tobacco leaves of any shape, but is preferably tobacco particles classified by the classification device 30 shown in FIG. 1.

[0104] The raw material mixed in the second step is formed into a pressure-molded sheet (molding step). Specifically, the raw material mixed in the second step is supplied to the extruder 50 (step S403). Because this raw material may be highly viscous, it may be supplied to the extruder 50 by a conveying device such as a belt conveyor. The raw material supplied to the extruder 50 is extruded into a sheet by the extruder 50. According to the manufacturing method shown in FIG. 4, the binder is mixed with water in advance to swell, thereby providing its binding function, and is then mixed with the first liquid raw material and the powder raw material, thereby increasing the viscosity of the raw material. As a result, the raw material is easier to handle and easier to extrude by the extruder 50. Furthermore, the increased viscosity of the raw material improves the strength of the tobacco sheet. Specifically, the raw material supplied to the extruder 50 is extruded into the die 60 by the extruder 50 (step S405), and the raw material is extruded into a sheet from the die 60 (step S406).

[0105] As shown in FIG. 4 , a second liquid raw material may be added to the raw material supplied to the extruder 50 (step S404). To extrude a raw material using the extruder 50, the raw material must have moisture suitable for the extrusion process. On the other hand, if the moisture content of the raw material is low enough to be extruded using the extruder 50, the raw material will be highly viscous, making it difficult to handle the raw material outside the extruder 50 (e.g., transporting the raw material from the mixer 40 to the extruder 50). Therefore, when the second liquid raw material is added to the raw material in the extruder 50, the moisture content of the raw material can be adjusted in the extruder 50, thereby reducing the amount of the first liquid raw material to be mixed in the mixer 40. This prevents the raw material from becoming too viscous in the mixer 40, making it easier to handle the raw material when it is supplied from the mixer 40 to the extruder 50.

[0106] This second liquid ingredient may contain water. In this case, the amount of the first liquid ingredient mixed in the mixer 40 can be reduced. As a result, the ingredients in the mixer 40 can be prevented from becoming too viscous, making it easier to handle the ingredients when supplying them from the mixer 40 to the extruder 50. The second liquid ingredient may contain one or more ingredients selected from the group consisting of water, glycerin, propylene glycol, a binder solution, and a liquid flavoring.

[0107] In the manufacturing method shown in Figure 4, the powdered raw material preferably contains tobacco and additives. In this case, by mixing the powdered raw material with the first liquid raw material in step S402, a tobacco raw material with increased viscosity due to the binder can be manufactured. The additives may also include, for example, one or more selected from the group consisting of pulp, cellulose (such as crystallized cellulose or cellulose powder), calcium carbonate, menthol, and powdered flavoring. The inclusion of additives in the powdered raw material can increase the strength of the tobacco sheet and impart flavor.

[0108] In the second process (step S402), the tobacco and additives may be placed separately in the mixer 40 and mixed with the swollen binder. In this case, each powdered raw material is mixed with a swollen binder separately, which further reduces the formation of lumps in the powdered raw materials and allows the raw materials to be mixed more uniformly.

[0109] In the manufacturing method shown in Figure 4, the first liquid raw material preferably contains an aerosol source and an additive. In this case, by mixing the swollen binder, the powder raw material, and the first liquid raw material in step S402, a tobacco raw material with an increased aerosol generation rate can be manufactured. The aerosol source may include, for example, one or more selected from the group consisting of glycerin and propylene glycol. Furthermore, the additive may include, for example, a liquid flavoring. By including a liquid flavoring in the liquid raw material, a flavor can be imparted to the tobacco sheet.

[0110] In the second process (step S402), the first liquid raw material and the powder raw material may be separately placed in the mixer 40 and mixed with the swollen binder. This allows the first liquid raw material and the powder raw material to be mixed separately, resulting in a more uniform mixing of the raw materials. Furthermore, in this case, it is preferable to place the first liquid raw material in the mixer 40 before the powder raw material in the second process (step S402) and mix it with the swollen binder. This allows the powder raw material to be added to the swollen binder and liquid raw material and mixed, thereby preventing the powder raw material from forming lumps and resulting in a more uniform mixing of the raw materials.

[0111] The manufacturing method shown in FIG. 4 may include, instead of steps S405 and S406, a step of extruding the raw materials mixed in the second step (step S402) using an extruder 50 and a step of forming the raw materials extruded from the extruder 50 into a sheet using at least one pair of rolling rollers facing each other in the vertical direction. More specifically, the raw materials may be formed into a sheet in stages using three sets of rolling rollers (i.e., six rolling rollers). Furthermore, the manufacturing method shown in FIG. 4 may include, instead of steps S405 and S406, a step of extruding the raw materials mixed in the second step (step S402) using an extruder 50 and a step of passing the raw materials extruded from the extruder 50 between two or more horizontally adjacent rolling rollers to form the raw materials into a sheet. More specifically, the raw materials may be passed between four horizontally adjacent rolling rollers to form the raw materials into a sheet in stages.

[0112] 5 is a flowchart of a method for producing a reconstituted pressure-formed tobacco sheet in a mixer 40, an extruder 50, and a die 60 according to a fourth embodiment. In the method for producing a reconstituted pressure-formed tobacco sheet according to the fourth embodiment, first, a powdered raw material containing at least tobacco and a first liquid raw material are mixed in the mixer 40 (mixing step: step S501). This tobacco may be tobacco leaves of any shape, but is preferably tobacco particles classified by the classifier 30 shown in FIG. 1. The raw material mixed in the mixing step is then supplied to the extruder 50 (step S502). Because this raw material may be highly sticky, it may be supplied to the extruder 50 by a conveyor such as a belt conveyor.

[0113] In the fourth embodiment, a second liquid raw material is further added to the raw material supplied to the extruder 50 (step S503). The raw material extruded from the extruder 50 is formed into a pressure-molded sheet (molding process). Specifically, the raw material supplied to the extruder 50 is extruded into a sheet shape. More specifically, the raw material supplied to the extruder 50 is extruded by the extruder 50 into a die 60 (step S504), and the raw material is extruded from the die 60 into a sheet shape (step S505).

[0114] As described above, in order to extrude the raw material using the extruder 50, the raw material needs to have moisture suitable for the extrusion process. On the other hand, if the moisture content of the raw material is low enough to be extruded using the extruder 50, the raw material will be highly viscous, making it difficult to handle the raw material outside the extruder 50 (for example, transporting the raw material from the mixer 40 to the extruder 50). Therefore, according to the fourth embodiment, the moisture content of the raw material can be adjusted in the extruder 50, thereby reducing the amount of the first liquid raw material to be mixed in the mixer 40. As a result, the raw material can be prevented from becoming too viscous in the mixer 40, making it easier to handle the raw material when supplying it from the mixer 40 to the extruder 50.

[0115] The second liquid raw material in step S503 may contain water. In this case, the amount of the first liquid raw material mixed in the mixer 40 can be reduced. As a result, the raw material can be prevented from becoming sticky in the mixer 40, making it easier to handle the raw material when supplying it from the mixer 40 to the extruder 50. The second liquid raw material may contain one or more selected from the group consisting of water, glycerin, propylene glycol, a binder solution, and a liquid flavoring.

[0116] The mixing step (step S501) may include a first step in which two or more types of powdered raw materials are introduced into the mixer 40 and mixed therein, and a second step in which, after the first step, a first liquid raw material is introduced into the mixer 40 and mixed with the powdered raw material. In this case, the two or more types of powdered raw materials are mixed in the first step before the powdered raw materials are mixed with the first liquid raw material, thereby enabling the powdered raw materials to be thoroughly mixed. In this second step, a first liquid raw material formed by premixing an aerosol source, water, and additives may be introduced into the mixer 40. In this case, the aerosol source, water, and additives contained in the first liquid raw material are premixed, enabling the powdered raw material and the first liquid raw material to be mixed more uniformly.

[0117] Alternatively, the mixing process (step S501) may include a first process of feeding the first liquid raw material into the mixer 40, and a second process of feeding the powdered raw material into the mixer 40 and mixing it with the first liquid raw material after the first process. In this case, the powdered raw material is mixed with the first liquid raw material, which can prevent the powdered raw material from clumping and allow the raw materials to be mixed more uniformly. In this second process, the tobacco, binder, and additives may be separately fed into the mixer 40 and mixed with the first liquid raw material. In this case, each powdered raw material is mixed separately with the first liquid raw material, which can further prevent the powdered raw material from clumping and allow the raw materials to be mixed more uniformly.

[0118] Alternatively, the mixing process (step S501) may include a first process in which water and a binder are introduced into the mixer 40 and mixed therein to swell the binder, and a second process in which, after the first process, the first liquid raw material and the powder raw material are introduced into the mixer 40 and mixed with the swollen binder. In this case, the binder is mixed with the first liquid raw material and the powder raw material in a state in which the binder is mixed with water and swelled in advance, thereby enabling the binder function of the binder to be exerted, thereby increasing the viscosity of the raw material. As a result, the raw material is easier to extrude through the extruder 50. Furthermore, the increased viscosity of the raw material improves the strength of the tobacco sheet. In this second process, the tobacco and the additives may be introduced separately into the mixer 40 and mixed with the swollen binder. In this case, each powder raw material is mixed separately with the swollen binder, thereby further preventing the powder raw material from forming lumps and achieving a more uniform mixing of the raw material.

[0119] Alternatively, in this second step, the first liquid raw material and the powder raw material may be separately placed in the mixer 40 and mixed with the swollen binder. This allows the first liquid raw material and the powder raw material to be mixed separately, resulting in a more uniform mixing of the raw materials. In this case, the second step may include placing the first liquid raw material in the mixer 40 before the powder raw material and mixing it with the swollen binder. This allows the powder raw material to be added to the swollen binder and the first liquid raw material and mixed, thereby preventing the powder raw material from forming lumps and resulting in a more uniform mixing of the raw materials.

[0120] The manufacturing method shown in FIG. 5 may include, instead of steps S504 and S505, a step of extruding the raw materials mixed in the second step (step S502) using an extruder 50 and a step of forming the raw materials extruded from the extruder 50 into a sheet using at least one pair of rolling rollers facing each other in the vertical direction. More specifically, the raw materials may be formed into a sheet in stages using three sets of rolling rollers (i.e., six rolling rollers). Furthermore, the manufacturing method shown in FIG. 5 may include, instead of steps S504 and S505, a step of extruding the raw materials mixed in the second step (step S502) using an extruder 50 and a step of passing the raw materials extruded from the extruder 50 between two or more horizontally adjacent rolling rollers to form the raw materials into a sheet. More specifically, the raw materials may be passed between four horizontally adjacent rolling rollers to form the raw materials into a sheet in stages.

[0121] Although the embodiments of the present invention have been described above, the present invention is not limited to the above embodiments, and various modifications are possible within the scope of the claims and the technical idea described in the specification and drawings. Note that any shape or material not directly described in the specification or drawings is within the scope of the technical idea of ​​the present invention as long as it achieves the functions and effects of the present invention.

[0122] 40: Mixer 50: Extruder 60: Die

Claims

1. A method for manufacturing a reconstituted pressure-formed tobacco sheet, comprising: a first step of putting a first liquid raw material into a mixer; a second step of, after the first step, putting a powdery raw material containing at least tobacco into the mixer and mixing it with the first liquid raw material; a forming step of forming the raw material mixed in the second step into a pressure-formed sheet.

2. The method for manufacturing a reconstituted tobacco sheet according to claim 1, wherein the powdery raw material contains tobacco, a binder, and an additive.

3. The method for manufacturing a reconstituted tobacco sheet according to claim 2, wherein the second step includes putting the tobacco, the binder, and the additive separately into the mixer and mixing them with the first liquid raw material.

4. The method for manufacturing a reconstituted tobacco sheet according to claim 1, wherein the first liquid raw material contains an aerosol source, water, and an additive.

5. The method for manufacturing a reconstituted tobacco sheet according to claim 1, including a step of supplying the raw material mixed in the second step to an extruder and a step of further adding a second liquid raw material to the raw material supplied to the extruder.

6. The method for manufacturing a reconstituted tobacco sheet according to claim 5, wherein the second liquid raw material contains water.

7. The method for manufacturing a reconstituted tobacco sheet according to claim 1, wherein the forming step includes a step of extruding the raw material mixed in the second step through an extruder into a die and a step of extruding the raw material from the die into a sheet shape.

8. The method for manufacturing a reconstituted pressure-formed tobacco sheet according to claim 1, wherein the forming step includes a step of extruding the raw material mixed in the second step through an extruder and a step of forming the raw material extruded from the extruder into a sheet shape by at least a pair of rolling rollers facing in the vertical direction.

9. The method for manufacturing a reconstituted pressure-formed tobacco sheet according to any one of claims 1 to 6, wherein the forming step includes a step of extruding the raw material mixed in the second step through an extruder and A method for manufacturing a reconstituted pressure-formed tobacco sheet, comprising a step of passing the raw material extruded from the extruder through between two or more rolling rollers adjacent in the horizontal direction to form it into a sheet shape.