Tobacco treatment

Abstract

The invention provides a process for producing dry ice expanded tobacco and treated dry ice expanded tobacco obtainable by this process. The invention also a combustible aerosol provision system, or an article or component therefor, comprising the treated dry ice expanded tobacco.

Description

[Technical Field]

[0001] This invention relates to a method, and more particularly to a method for processing dry ice expanded tobacco (DIET). [Previous Technology]

[0002] After harvesting, tobacco material can be cured to produce consumer tobacco leaves. Further processing of the tobacco material, such as aging or fermentation, can enhance its sensory properties. However, these methods can be lengthy and the quality of the resulting tobacco material may be inconsistent. Later stages of tobacco processing, used to enhance or add flavor and aroma to tobacco material, typically involve adding one or more additives to the tobacco and may require additional processing steps and equipment, potentially incurring costs and time. [Summary of the Invention]

[0003] According to a first aspect of the present invention, a method is provided for processing dry ice expanded tobacco (DIET) encapsulated in a water-retaining material, the method comprising exposing the tobacco to an ambient processing temperature exceeding 45°C, wherein the tobacco has a packing density of 60 to 160 kg / m³ at the start of the method, and a moisture content of about 10% to 23% before and during processing. This method can be used to produce tobacco with desired sensory properties.

[0004] Expanded DIET can be optionally used in combustible aerosol delivery systems. Therefore, according to a second aspect of the invention, a method for producing DIET for use in combustible aerosol delivery systems is provided, the method comprising exposing DIET encapsulated in a water-retaining material to an ambient processing temperature exceeding 45°C, wherein the tobacco has a packing density of 60 to 160 kg / m³ at the start of the method and a moisture content of about 10% to 23% before and during processing. This method can be used to produce tobacco with desired sensory properties.

[0005] The features of the states and embodiments described herein can be applied to the first and second states of the present invention.

[0006] The method of the first or second state may include encapsulating or fixing the tobacco in a water-retaining material before exposing the tobacco to the specified conditions.

[0007] According to a third state sample, a processed dry ice expanded tobacco that can be obtained by a method of a first or second state sample is provided.

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

[0009] A fifth state provides a fraction for use in a flammable aerosol supply system comprising a treated dry ice expanded tobacco material of the third or fourth state.

[0010] A sixth state sample provides an object for use in a flammable aerosol supply system, the object comprising a component of the fifth state sample.

[0011] Another state provides an aerosol supply system comprising an object of a third or fourth state of treated dry ice expanded tobacco, a component of the fifth state, or a sixth state. The method described herein may further comprise incorporating the treated dry ice expanded tobacco material into a combustible aerosol supply system or a component or object used for the combustible aerosol supply system.

[0012] The method described herein may further comprise incorporating the treated dry ice expanded tobacco material into the mix. The dopant may be applied to a combustible aerosol supply system or a component or object used in the combustible aerosol supply system. Appropriate amounts of treated dry ice expanded tobacco in the mixes are described below.

[0013] Yet another state provides a third or fourth state use of treated over-dry ice expanded tobacco material for manufacturing components for use in a combustible aerosol supply system.

[0014] Treated DIET can be used to prepare tobacco extracts. Another state provides a tobacco extract manufactured from a third or fourth state of DIET. [Implementation]

[0016] Expanded tobacco materials are tobacco materials that have been subjected to expansion methods. Swelling involves increasing the volume of the cellular structure of the tobacco material, which can lead to an increase in the area and spacing between any fibers present in the tobacco material. After being subjected to the expansion method, the tobacco material has a higher filling value but lower density than the tobacco material before the expansion method. Expanded tobacco may be blended with other types of tobacco, such as providing smoking objects having a lower total weight than the object of habituation. Reducing total weight provides many advantages, such as reduced transportation costs. Furthermore, reducing object weight may also have a positive impact on the environment, as less energy is required to transport the object. In addition, consumers may prefer to carry and use lightweight objects. Expanded tobacco types include dry ice expanded tobacco and expanded terrier. Expansion is formed by expanding the smoke with steam.

[0017] However, expanded tobacco materials may impair the sensory properties of tobacco blends containing them, which may limit the amount of expanded tobacco materials that may be included in the blends while maintaining an acceptable flavor profile.

[0018] This invention relates to a method for processing dry ice expanded tobacco (DIET). The processed DIET can be used in combustible aerosol delivery systems. The processing advantageously alters the sensory properties of the DIET. However, the inventors have found that when other types of expanded tobacco are subjected to the same processing, such desired changes in sensory properties are not observed. In particular, expert smokers have determined that there is no significant change in the flavor profile between processed and unprocessed expanded stems (i.e., expanded stem tobacco before and after the processing method described herein). In contrast, a change in the flavor profile between processed and unprocessed DIET (i.e., DIET before and after the processing method described herein) has been found. That is, the inventors have unexpectedly discovered that the method of the present invention is particularly suitable for improving the sensory properties of DIET, but not for improving the sensory properties of expanded stems.

[0019] The advantageous changes in the sensory properties of DIET tobacco provided by the method herein mean that treated tobacco can be added to tobacco blends (e.g., for use in smoking objects) in higher amounts than untreated DIET tobacco without impairing the sensory properties of the tobacco blends.

[0020] The inventors have also discovered that the high filling value of dry ice-expanded tobacco is maintained during the method of the present invention. The filling value of dry ice-expanded tobacco may even increase during the method.

[0021] As used herein, the term "treated tobacco" refers to tobacco that has undergone the treatment methods described herein, while the term "untreated tobacco" refers to tobacco that has not yet undergone the treatment methods. The tobacco used in the method of the present invention is dry ice expanded tobacco (DIET).

[0022] Tobacco undergoes several steps before being consumed by consumers. In tobacco fields, the following steps are typically performed by tobacco farmers: sowing; transplanting; growing; harvesting; and maturation.

[0023] Generally, tobacco undergoes curing after harvest to reduce its moisture content, typically from about 80% to about 20% or less. Many different curing methods can be used, including air-drying, flue-curing, and sun-drying. During curing, the tobacco undergoes certain chemical changes, turning from green to yellow, orange, or brown. Temperature, relative humidity, and packing density are carefully controlled to try to avoid scorching and spoilage, which are common problems during curing.

[0024] In a green leaf threshing (GLT) factory, tobacco is sold by tobacco farmers and typically undergoes the following steps: re-grading; blending of fresh tobacco leaves; conditioning; removal of stems by destemming or threshing (omitted if whole leaves are used); drying; and packaging.

[0025] Usually, after maturation, the stems can be removed from the leaves. This can be done by threshing, where a machine separates the midrib and part of the leaf veins from the leaf. Another method is to remove the stems manually from the leaves, also known as "hand-peeling". Alternatively, the tobacco can be "butted", which means removing the thicker part of the stem while leaving the rest of the tobacco leaf intact.

[0026] In addition to aging, tobacco can be further processed to enhance its flavor and aroma. Aging and fermentation are known techniques for enhancing the flavor and aroma of tobacco. These methods can be applied to tobacco materials such as threshed leaves, hand-peeled leaves, cut leaves, and / or whole-leaf tobacco.

[0027] Aging is usually carried out after tobacco has undergone curing, threshing (or cutting or hand-peeling), and packaging. Aged tobacco includes Oriental tobacco that has undergone flue curing and air-drying curing. During aging, tobacco can usually be stored at a temperature of about 20°C to about 40°C and at the relative humidity of the individual country of origin / aging, or under controlled warehouse conditions, for about 1 to 3 years.

[0028] Importantly, during the aging process, the moisture content of the tobacco must be maintained at a relatively low level, for example, at most about 10-13%. If the moisture content is higher, the tobacco will become moldy.

[0029] Fermentation is a method used for specific tobaccos, including dark-colored air-dried cured tobacco, cured oriental tobacco, and cigar tobacco, to give the tobacco a more consistent color and alter its aroma and flavor. Fermentation is generally not used for flue-cured or light-colored air-dried cured tobacco. Generally, fermentation is also not applied to DIET tobacco.

[0030] Fermentation parameters, such as the moisture content of the tobacco and surrounding conditions, vary depending on the type of tobacco undergoing fermentation. Generally, the fermentation humidity is approximately equal to the moisture content of the tobacco when it is received by the farmer (about 16-20%), or slightly higher after processing. Care must be taken to avoid fermentation at excessively high moisture content, which can lead to various forms of spoilage. The duration of fermentation can vary, ranging from several weeks to several years.

[0031] Generally, fermentation involves processing large quantities of tobacco and affects the entire leaf, with the stems removed immediately after processing. The tobacco can be piled into a large heap, with the peripheral tobacco moved to the center of the heap at regular intervals. Alternatively, the tobacco can be placed in a chamber with a volume of several square meters. Processing such a large quantity of tobacco can be a very cumbersome and / or time-consuming operation.

[0032] Obviously, fermentation relies on the activity of microorganisms to induce changes within the tobacco material. The fermentation conditions, including temperature and moisture content, are selected to enhance microbial activity during fermentation. For example, the processing temperature must typically be controlled within the range of 38-40°C during fermentation. In most, if not all, cases of tobacco fermentation rely on microorganisms already present in the tobacco material. However, it is possible to introduce suitable microorganisms into the tobacco material at the initial stage of the fermentation process.

[0033] After the above processing, for example before incorporating tobacco into tobacco-containing products, the tobacco is usually transported to other places for further processing. Before incorporating tobacco into smoking objects such as cigarettes, the tobacco is usually unpacked, processed, blended with other tobacco styles and / or types and / or varieties, cut, dried, blended with other tobacco materials, and transferred to the cigarette manufacturing department.

[0034] Alternatively, tobacco can be treated with additives to enhance or improve its flavor and aroma. However, this requires additional processing steps and equipment, making tobacco preparation methods lengthy and generally expensive. Furthermore, it is desirable to have a tobacco material that possesses a flavor and aroma that consumers prefer, without any additives being applied to achieve this. This is, for example, the case for consumers who want natural tobacco products that simultaneously have a pleasant flavor and / or taste. Generally, additives are applied at places such as cigarette factories where smoking objects are produced, although the point of application can vary.

[0035] In some embodiments, the method for processing tobacco material as described herein produces dry ice-inflated tobacco material with desired sensory properties in a shorter time than conventional techniques such as fermentation and aging, without the addition of flavoring agents or aroma additives. In some embodiments, the method of the present invention does not involve fermentation or substantially does not involve fermentation. This can be demonstrated by the presence of very little or no microbial content in the tobacco material at the end of the method. Thus, in one embodiment, the microbial content of the tobacco material at the end of the method is lower than the microbial content of the tobacco material at the beginning of the method.

[0036] In some embodiments, the method for processing dry ice expanded tobacco material described herein produces tobacco with an improved flavor profile or improved sensory properties (compared to the flavor profile of untreated or conventionally cured dry ice expanded tobacco). This means a reduction in undesirable or irritating substances while retaining the tobacco flavor characteristics visible under conventional curing. As used herein, the terms "improved" or "enhanced" in the context of flavor or sensory properties mean that expert smokers perceive an improvement or enhancement in taste or flavor quality. This may, but may not, include an enhancement of flavor.

[0037] In some embodiments, the method described herein for processing dry ice-expanded tobacco material produces a tobacco material that has reduced at least one undesirable taste or flavor characteristic. For example, it can reduce dryness and unpleasant off-notes.

[0038] In some embodiments, the method described herein can be used to improve the sensory properties of dry ice-expanded tobacco starting materials with poor sensory (e.g., taste) properties. It has been found that at least one effect of processing on dry ice-expanded tobacco materials is the removal or reduction of sensory factors that negatively affect the overall sensory properties of the tobacco material. In some embodiments, the method can also result in an increase in positive sensory properties.

[0039] In some embodiments, the method of processing dry ice-expanded tobacco can be adjusted to produce processed material with specific selected sensory characteristics. This may, for example, involve adjusting one or more parameters of the method.

[0040] In some embodiments, the method described herein for processing dry ice-expanded tobacco material transforms the flavor profile of the tobacco (compared to the flavor profile of untreated tobacco or tobacco treated only by conventional aging methods). This means that the sensory properties of the processed tobacco undergo a significant change, resulting in a change in the flavor characteristics of the tobacco compared to the flavor characteristics of untreated DIET tobacco. As used herein, the term "transformation" in the context of flavor or sensory properties means, as determined by an expert smoker, a change from one overall flavor or sensory characteristic to another. This may include improvements and / or enhancements in flavor or flavor quality.

[0041] In some embodiments, including those in which the sensory properties of tobacco starting materials are altered, the processing not only reduces or removes sensory factors with negative effects, but also introduces or increases sensory factors with positive effects. For example, in some embodiments, the methods described herein result in an increase in the products of the Maillard reaction, many of which are known to contribute to the production of the desired sensory properties.

[0042] The sensory properties of tobacco material mentioned herein may refer to, for example, the sensory properties of the tobacco material itself when used orally by a consumer. Alternatively, this may refer to the sensory properties of the smoke produced by burning the tobacco material or the vapor produced by heating the tobacco material. In some embodiments, when the product is used or consumed, the treated tobacco material provides a tobacco product comprising the tobacco material having the desired sensory properties.

[0043] The tobacco material used in this disclosure is dry ice-expanded tobacco. As used herein, the term "tobacco material" includes any part and any related byproducts, such as leaves or stems, from any member of the genus *Nicotiana*. The tobacco material used in this invention is preferably derived from the species *Nicotiana tabacum*.

[0044] Dry ice expanded tobacco of any type, style, and / or variety can be processed. Examples of tobaccos that can be used include, but are not limited to, Virginia, Burley, Oriental, Commum, Amarelinho, and Maryland tobaccos, as well as any blends of these types. Those skilled in this technique will recognize that different types, styles, and / or varieties of tobacco will result in different sensory properties.

[0045] In some embodiments, the tobacco material includes leaf tobacco material. The tobacco may contain leaf material of about 70% to 100% by weight. For example, the tobacco may contain leaf material of about 80% to 100% by weight, such as about 90% to about 99% leaf material.

[0046] The tobacco material may comprise up to 50%, 60%, 70%, 80%, 90%, or 100% leaf tobacco material by weight. In some embodiments, the tobacco material comprises up to 100% leaf tobacco material by weight. In other words, the tobacco material may comprise substantially all or all of leaf tobacco material.

[0047] In certain embodiments, the tobacco material comprises leaf tobacco, is substantially composed of leaf tobacco, or is composed of leaf tobacco, such as leaf tobacco containing leaf Virginia tobacco. In some cases, the leaf tobacco may be selected from Virginia or a blend of Virginia and Burley tobacco. The weight ratio of Virginia to Burley may be from 1:10 to 10:1, such as 1:5 to 5:1, 1:2 to 2:1, 1:1.5 to 1.5:1, or 1.2:1 to 1:1.2.

[0048] Alternatively or additionally, the tobacco material may comprise at least 50%, at least 60%, at least 70%, at least 80%, at least 90% or at least 95% leaf tobacco material by weight.

[0049] When the tobacco material includes leaf tobacco material, the leaves may be in whole leaf form or cut form. Typically, tobacco material (such as leaf tobacco) is in cut form. Using cut tobacco reduces the time required for impregnation / permeation of tobacco with liquid carbon dioxide during dry ice expansion.

[0050] In some embodiments, the DIET tobacco material includes stem tobacco material. The tobacco may contain up to about 20% stem by weight, such as up to about 15% stem by weight. For example, the tobacco material may contain 1-20% stem by weight and 80-99% leaf tobacco by weight, such as 5-15% stem by weight and 85-95% leaf material by weight.

[0051] The pre-prepared DIET can be processed according to the method of the present invention. For example, DIET can be commercially available. Alternatively, the method may involve dry ice expansion of tobacco material to provide DIET, followed by processing of the DIET as described herein.

[0052] Methods for forming DIET are known in this art. For example, dry ice expansion involves permeating (or impregnating) tobacco with liquid carbon dioxide under pressure, such as immersing and soaking the tobacco in liquid carbon dioxide. Excess liquid and / or gaseous carbon dioxide can be recovered for reuse, for example, by draining the liquid. The method may include, for example, converting liquid carbon dioxide in the tobacco into solid carbon dioxide (dry ice) by reducing the pressure. When the system is not pressurized, the carbon dioxide in the tobacco will solidify into dry ice. This phase change can occur at the triple point pressure of CO2 (60.4 psig and -69.83 degrees Fahrenheit). The solid carbon dioxide is then subjected to conditions of solid carbon dioxide evaporation (or solid carbon dioxide undergoes sublimation to form carbon dioxide), thereby causing the tobacco material to expand. For example, tobacco material containing solid carbon dioxide can be rapidly heated as follows. Upon heating, the dry ice sublimates to form gaseous carbon dioxide, which forces the tobacco to expand.

[0053] A suitable method for dry ice expansion may involve impregnating the cellular structure of tobacco with liquid carbon dioxide. Typically, the impregnated tobacco is cut tobacco. Suitable conditions for this impregnation step may involve contacting the tobacco material in the impregnation chamber with liquid carbon dioxide at a temperature of -40 to -10°C, such as -25 to -15°C, for approximately 1 to 10 minutes, such as 2 to 8 or 3 to 7 minutes, under pressure. The pressure may be, for example, 435 psig (3000 kPa). A suitable cut width is illustrated in the following illustration of Figure 1. Immediately prior to impregnation, the tobacco material may have a moisture content of 10 to 40%, such as 15 to 35% or 20 to 30%. After the impregnation step, the method typically then involves sufficiently reducing the pressure within the impregnation chamber to cause the liquid carbon dioxide to solidify within the cellular structure. For example, the pressure may be reduced to atmospheric pressure (1 atm). The method may then involve rapidly heating the tobacco to sublimate the solid carbon dioxide within the tobacco cells, thereby causing the tobacco to expand. This rapid heating can be performed by introducing tobacco material containing solid carbon dioxide into an airflow at a temperature ranging from 250 to 400 °C, such as 300-360 °C or about 330 °C. The method may subsequently include hydrating the dry ice-expanded tobacco to a desired initial moisture content for further processing by the method of the present invention.

[0054] Figure 1 illustrates a suitable exemplary method for preparing dry ice-expanded tobacco. Several bundles of tobacco material are sliced ​​and then conditioned with water and steam. The tobacco material can be any of the tobacco materials described herein. Leaf tobacco, particularly leaf Virginia tobacco, is particularly preferred. One reason for this is that it exhibits the desired sensory properties and has a relatively low level of undesirable compounds compared to other tobacco varieties. Another advantage of using Virginia tobacco is that it tends to expand easily during the expansion process. In some embodiments, in addition to leaves, stem tobacco may also be used. After conditioning, the conditioned tobacco material is blended with other conditioned tobacco materials or mixed before being fed to the cutter. Preferably, the cutter cuts the tobacco material at 25 to 28 cuts per inch (CPI). A cut width of CPI of 25 is particularly preferred, although other cut widths may also be used. Cutting the tobacco material increases its surface area, thus reducing the time spent impregnating with liquid during the impregnation step. Such cutting widths can also increase the fill value of the final material.

[0055] After wetting and mixing the cutting material with the wet material, the material has a moisture content of approximately 26%. This material is then fed into an impregnation machine container, where it is subsequently loaded with carbon dioxide under pressure at a temperature of -20 °C for approximately 6 minutes. These conditions ensure that the carbon dioxide remains in liquid form and has sufficient time to penetrate and be absorbed into the tobacco material. Afterward, the impregnated tobacco material is fed into a sublimator, where the pressure is reduced to solidify the liquid carbon dioxide. The impregnated tobacco material is then heated in a gas stream at a temperature of 330 °C. This causes the moisture and carbon dioxide in the tobacco material to evaporate rapidly, resulting in its expansion.

[0056] Other gas temperatures may be used. For example, the gas temperature may be between approximately 250 °C and approximately 400 °C or higher. The maximum temperature is preferably lower than the combustion temperature of the tobacco material. Higher temperatures can improve the expansion rate and thus improve the efficiency of the method. The filler value of the tobacco material can also be controlled by changing the temperature. Higher temperatures can cause more moisture to be expelled from the material, and thus the final material has a higher filler value. Conversely, using a lower temperature may reduce the filler value of the final material.

[0057] High gas temperatures can be achieved by any suitable means (e.g., by heating the air using a heating plate or burner). The tobacco material at the end of sublimation is relatively dry and has a moisture content of about 6%. The moisture content is increased to about 12% to 14% (often a target of 13.6%) by hydrating it in a rearrangement cylinder to produce the final expanded tobacco material. The expanded material may have a filling value of at least about 6 cm³ / g.

[0058] When referring to "moisture," it is important to understand the widely varying and conflicting definitions and terminology used. Commonly, "moisture" or "moisture content" is used to refer to the water content of a material, but in certain industries, such as the tobacco industry, it is necessary to distinguish between the "moisture" in water content and the "moisture" in oven volatiles. Water content is defined as the percentage of water contained in the total mass of a solid substance. Volatiles are defined as the percentage of volatile components contained in the total mass of a solid substance. This includes water and all other volatile compounds. Oven dry mass is the mass of volatile substances retained after being expelled by heating. It is expressed as a percentage of the total mass. Oven volatiles (OV) are the mass of volatile substances after expulsion.

[0059] Moisture content (oven volatiles) can be measured as the mass reduction of a sample when it is dried in a forced-ventilation oven at a temperature adjusted to 110°C ± 1°C for three hours ± 0.5 minutes. After drying, the sample is allowed to cool to room temperature in a desiccator for approximately 30 minutes to allow the sample to cool.

[0060] Unless otherwise stated, the moisture content mentioned herein refers to oven volatiles (OV).

[0061] Figure 2 shows cross-sections of the tobacco leaf before (top) and after (bottom) dry ice expansion. The scale bars (center, bottom) of each image correspond to a distance of 100 micrometers. The expansion of the tobacco material during the dry ice expansion method can be seen by comparing these images.

[0062] Different known types of expanded tobacco to DIET are expanded stems (which may also be called expanded stems or steam-treated stems (STS)). The method of forming expanded stems usually involves steam-treating the stems, which causes the material to expand and the filling value to increase.

[0063] Figure 3 illustrates one such method for expanding tobacco stems. Tobacco is loaded into a feeder. The tobacco stems can be derived from any variety of tobacco described herein. After the addition of water, the moisture content of the stems is about 34%. The mixture is then blended and / or thoroughly mixed with stems from other batches, at which point the stems have a moisture content between about 30% and about 40%, such as about 36%. The material is then cut to ensure that the stem portions have uniform dimensions. This cutting can help to further increase the filler value of the material. Water is then applied to the cut stems to increase their moisture content to between about 35% and about 45%. The relatively high moisture level obtained in this step helps to increase the expansion of the stems during subsequent expansion steps. The material is then subjected to steam treatment at a temperature exceeding 100°C (e.g., using steam or superheated steam). This causes the stems to expand and their filler value to increase. Steam can be applied at a rate of at least 200 kg / hr, such as greater than 300 kg / hr or greater than 350 kg / hr, for example, from about 375 kg / hr to about 500 kg / hr. Higher application rates can also be used. Using a higher steam application rate can increase the yield. After dust removal with a dust collector, the expanded stems can be stored.

[0064] As described in the invention, the moisture content of DIET before and during treatment is between about 10% and about 23%. As used herein, the term "moisture content" refers to the percentage of oven volatiles present in the DIET material.

[0065] In some embodiments, the moisture content of DIET before and during treatment is between about 10% and 15.5%, optionally between about 10.5% and 15% or between about 11% and 14%. The moisture content of DIET may be about 10%, about 11%, about 12%, about 13%, about 14%, about 15%, about 16%, about 17%, about 18%, about 19%, about 20%, about 21%, about 22% or about 23%.

[0066] In some embodiments, for example, when the moisture content of DIET is between about 10% and 20%, or optionally between about 10% and 18%, it is not necessary to dry the tobacco again after the treatment method.

[0067] The DIET material is encapsulated, for example, within a water-retaining material to limit moisture loss and maintain the desired moisture level during the process. The method may further include encapsulating or fixing the DIET material within a water-retaining material prior to processing the tobacco according to the method of the invention.

[0068] The DIET material may be completely sealed within the water-retaining material. Alternatively, the DIET material may not be completely sealed within the water-retaining material. In some embodiments, the water-retaining material surrounds the DIET material. In other embodiments, the water-retaining material surrounds a storage container containing the DIET material. In some embodiments, the DIET material is placed inside the water-retaining container. Thus, the method of the present invention can be performed on the DIET material, wherein the water-retaining material has surrounded the DIET material or wherein the water-retaining material has surrounded a storage container containing the DIET material. Furthermore or alternatively, the method of the present invention can be performed on the DIET material already placed inside a water-retaining container.

[0069] The water-retaining material can be any material that is sufficiently impermeable to water to retain the desired amount of moisture during the treatment process. The amount of moisture retained in the DIET material can be at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 91%, at least 92%, at least 93%, at least 94%, at least 95%, at least 96%, at least 97%, at least 98%, at least 99%, at least 99.5%, or 100% of the moisture present in the DIET material before treatment. In some embodiments, the moisture content of the DIET material is retained between 99% and 100% during the process.

[0070] The water-retaining material should ideally resist degradation during the tobacco processing method. For example, the water-retaining material should ideally withstand the temperature of the processing method without decomposing into a permeable state or releasing compounds that could be absorbed by the tobacco material. Therefore, the temperature reached by the DIET material during the processing should be taken into consideration when selecting the water-retaining material.

[0071] The water-retaining material may comprise a flexible material. This flexible material may wrap around the DIET material and / or form a small pouch for holding the DIET. In some embodiments, the water-retaining material comprises a plastic material. In some embodiments, the water-retaining material comprises a flexible polymeric material, optionally a polymer or plastic film. In some embodiments, the water-retaining material comprises polyethylene. In some embodiments, the water-retaining material comprises polyester, nylon, and / or polypropylene. In some embodiments, the water-retaining material is Polyliner®. Polyliner® is available from numerous suppliers, including Plastrela Flexible Packaging in Brazil.

[0072] Alternatively or additionally, the water-retaining material may comprise a rigid material, such as a metal, for example, formed into a vessel or container. In these embodiments, a separate storage container as discussed below may not be necessary.

[0073] In embodiments where the DIET material reaches a temperature of about 100°C or higher, the water-retaining material may be pressure-resistant.

[0074] In some embodiments, the method may include allowing the tobacco material to rest for a period of time while encapsulated in a water-retaining material before exposing it to ambient processing temperatures. The resting period may be at least 15 days, such as at least 30 days. For example, the resting period may be from 15 to 75 days, such as 20 to 60 days or 30 to 45 days.

[0075] At the start of the method, the DIET material has a packing density of 60 to 160 kg / m³. In some embodiments, the DIET material has a packing density of 70-140 kg / m³, 90-135 kg / m³, 100-130 kg / m³, or 105-125 kg / m³ at the start of the treatment. The method / treatment begins when the DIET is exposed to an ambient processing temperature as defined herein. That is, when the DIET is exposed to an ambient processing temperature, the DIET has a packing density of 60 to 160 kg / m³, such as 70-140 kg / m³, 90-135 kg / m³, 100-130 kg / m³, or 105-125 kg / m³.

[0076] The packing density described herein is calculated by dividing the weight of the DIET by the volume occupied by the DIET. The packing density described herein should be calculated based on the total weight of the tobacco material, including any water / moisture in the tobacco material.

[0077] When the volume of the storage container, the volume enclosed by the water-retaining material and the volume occupied by DIET are substantially the same or substantially the same (for example, when the storage container is substantially completely or completely filled with DIET material and tightly enclosed, wrapped or fixed in the water-retaining material), the packing density can be calculated by dividing the weight of the tobacco placed in the storage container by the volume of the storage container.

[0078] The volume of the storage container and / or the volume encapsulated by the water-retaining material (which may be substantially the same) can be selected to achieve the desired packing density of the desired amount of tobacco to be processed, while allowing the processing of the tobacco to occur at an appropriate rate.

[0079] If the DIET does not occupy the entire volume of the water-retaining material, the volume occupied by the DIET can be calculated by subtracting the volume of any empty space (e.g., any empty space above the tobacco material after it has been placed in the water-retaining material and the storage container) from the total volume of the water-retaining material.

[0080] The packing density of the DIET material during and / or after treatment may be similar to or substantially similar to the packing density of the DIET material at the start of the method. In some cases, the volume occupied by the DIET material decreases during treatment, thus increasing the packing density of the DIET material during and / or after treatment.

[0081] The DIET material may be placed in the storage container after being encapsulated or secured within a water-retaining material. Alternatively, the DIET material may be placed in the storage container and subsequently encapsulated or secured within a water-retaining material, such as by wrapping the storage container with a water-retaining material. Placing the DIET in the container facilitates the handling of the tobacco.

[0082] Alternatively or additionally, the container may be placed on its side. This configuration may be particularly advantageous when the DIET material is contained in tobacco leaves that are placed horizontally in the storage container, as placing the storage container on its side achieves a more uniform packing density.

[0083] In some embodiments, the container has a volume between about 0.2 m³ and about 1.0 m³, and optionally between about 0.4 m³ and about 0.8 m³. In some embodiments, the container has a volume of about 0.7 m³.

[0084] In some embodiments, the volume occupied by the DIET material at the start of the method is between about 0.2 m³ and about 1.0 m³, and optionally between about 0.4 m³ and about 0.8 m³. In some embodiments, the volume occupied by the DIET material at the start of the method is about 0.7 m³.

[0085] In some embodiments, the storage container is a tobacco box known as a C-48 box. A C-48 box is generally made of cardboard and has dimensions of approximately 115 x 70 x 75 cm.

[0086] DIET can be placed in a tobacco processing area. As used herein, the term "tobacco processing area" refers to an area where the processing method is performed, which may be a room or chamber. The surrounding process conditions, i.e., the conditions of the tobacco processing area, can be controlled during the process. This can be achieved by placing DIET material encapsulated or secured within a water-retaining material in a controlled environment such as a chamber. The DIET material can be placed on one or more shelves within the chamber to allow optimal ventilation to maintain constant surrounding process conditions around the tobacco. These shelves may have one or more racks containing rods with gaps and / or other openings between the rods to help maintain constant surrounding process conditions around the tobacco.

[0087] The ambient processing humidity can be maintained at a certain level to avoid significant moisture loss from the DIET material. As used herein, the term "ambient processing humidity" refers to the humidity of the tobacco processing area. As used herein, the term "ambient relative processing humidity" refers to the relative humidity of the tobacco processing area.

[0088] In some embodiments, the ambient relative processing humidity is approximately 65%. The ambient relative processing humidity may be at least 40%, at least 45%, at least 50%, at least 55%, at least 60%, at least 65%, or at least 70%.

[0089] The ambient processing temperature is at least about 45°C. In some embodiments, the ambient processing temperature is at least about 50°C. In some embodiments, the ambient processing temperature may be maintained at more than 55°C, and optionally at about 60°C. As used herein, the term "ambient processing temperature" refers to the temperature of the tobacco processing area.

[0090] In some embodiments, the ambient processing temperature is at least 46°C, at least 47°C, at least 48°C, at least 49°C, at least 50°C, at least 51°C, at least 52°C, at least 53°C, at least 54°C, at least 55°C, at least 56°C, at least 57°C, at least 58°C, at least 59°C, at least 60°C, at least 61°C, at least 62°C, at least 63°C, at least 64°C, at least 65°C, at least 66°C, at least 67°C, at least 68°C, at least 69°C, or at least 70°C. In some embodiments, the ambient processing temperature is at most 60°C, at most 70°C, at most 75°C, at most 80°C, at most 85°C, at most 90°C, at most 95°C, at most 100°C, at most 105°C, at most 110°C, at most 115°C, or at most 120°C.

[0091] In the embodiment with an ambient processing temperature of approximately 45°C, the ambient processing humidity can be approximately 30-70 g water / m³. In the embodiment with an ambient processing temperature of approximately 55°C, the ambient processing humidity can be approximately 40-80 g water / m³. In the embodiment with an ambient processing temperature of approximately 60°C, the ambient processing humidity can be approximately 50-110 g water / m³. In the embodiment with an ambient processing temperature of approximately 70°C, the ambient processing humidity can be approximately 50-160 g water / m³. In the embodiment with an ambient processing temperature of approximately 80°C, the ambient processing humidity can be approximately 50-230 g water / m³. In the embodiment with an ambient processing temperature of approximately 90°C, the ambient processing humidity can be approximately 50-340 g water / m³. In embodiments where the ambient processing temperature is approximately 100°C or higher, the ambient processing humidity can be approximately 50-500 g water / m³.

[0092] In some embodiments, the ambient processing temperature is 60°C and the ambient relative processing humidity is 60%.

[0093] During the method, the temperature of the DIET material reaches the ambient processing temperature. The DIET material can reach the ambient processing temperature within a short period of time. For example, the DIET material can reach the ambient processing temperature in 4 to 10 days, optionally in 5 to 9 days, in 7 to 9 days, and / or in 4 to 7 days.

[0094] To achieve this, the amount of DIET processed can be optimized to allow heat to be transferred to the center of the tobacco material quickly enough. The rate at which the temperature of the DIET material rises and reaches the ambient processing temperature will depend on many factors, including the ambient processing temperature, the density of the DIET, and the total amount of DIET processed.

[0095] In some embodiments, the DIET material reaches a temperature exceeding 55°C and / or at least 60°C within approximately 9 days. In some embodiments, the DIET material reaches a temperature exceeding 55°C and / or at least 60°C within approximately 7 days. In some embodiments, the DIET material reaches a temperature exceeding 55°C and / or at least 60°C within approximately 5 days. In these embodiments, the ambient processing temperature may be 60°C.

[0096] In some embodiments, the DIET material is heated to a temperature of at least about 55°C or at least about 60°C. Alternatively, the DIET material may be heated to a temperature of at most about 80°C, at most about 85°C, at most about 90°C, at most about 95°C, or at most about 100°C.

[0097] In some embodiments, by employing a higher ambient processing temperature, the beneficial effects of the processing according to the present invention can be achieved in a shorter processing period.

[0098] The temperature of the DIET material can be increased during the processing method to reach a second temperature higher than the ambient processing temperature. This can be achieved with the assistance of an exothermic reaction that occurs during the processing method.

[0099] In some embodiments, the DIET material reaches a second temperature exceeding the ambient processing temperature. In some embodiments, the second temperature exceeds the ambient processing temperature by at least 1°C. The temperature exceeds the ambient processing temperature by at least 2°C, at least 3°C, at least 4°C, at least 5°C, at least 7°C, at least 10°C, at least 12°C, at least 15°C, at least 17°C, or at least 20°C. In some embodiments, the DIET material reaches a second temperature exceeding the ambient processing temperature within approximately 7 to 13 days, and / or within approximately 13 days or within approximately 11 days. In some embodiments, the DIET material reaches a second temperature exceeding the ambient processing temperature by at least 5°C within approximately 11 to 13 days.

[0100] The temperature of the DIET material during the processing method may reach up to 60°C, up to 65°C, up to 70°C, up to 75°C, up to 80°C, up to 85°C, up to 90°C, up to 95°C, up to 100°C, up to 105°C, up to 110°C, up to 115°C, up to 120°C, up to 125°C, up to 130°C, up to 135°C, up to 140°C, up to 145°C, or up to 150°C.

[0101] Alternatively or additionally, the temperature of the DIET material during the processing method may reach at least 60°C, at least 65°C, at least 70°C, at least 75°C, at least 80°C, at least 85°C, at least 90°C, at least 95°C, at least 100°C, at least 105°C, at least 110°C, at least 115°C, at least 120°C, at least 125°C, at least 130°C, at least 135°C, at least 140°C, at least 145°C, or at least 150°C. In practice, the upper limit temperature may be limited by the heat resistance of the water-retaining material.

[0102] In some embodiments, the temperature of the DIET material can reach between about 55°C and about 90°C, between about 55°C and about 80°C, or between 60°C and about 70°C.

[0103] DIET can be encapsulated or fixed in a water-retaining material and exposed to ambient processing temperatures for a sufficiently long period of time to allow the DIET to develop the desired sensory properties, and for a sufficiently short period of time to avoid causing unnecessary delays in the tobacco supply chain.

[0104] The DIET material is encapsulated or fixed within a water-retaining material for a period of time, and is subjected to a suitable ambient processing temperature and ambient processing humidity that would cause the tobacco temperature to rise to or exceed a critical temperature, wherein the moisture content of the tobacco is between approximately 10% and 23%. In some embodiments, the critical temperature is 55°C, 60°C, or 65°C.

[0105] In some embodiments, the DIET material is exposed to ambient processing temperatures exceeding 45°C (or any ambient processing temperature disclosed herein) for approximately 5 to 65 days, such as 10 to 50 days, 20 to 45 days, 30 to 40 days, or 35 to 40 days.

[0106] In other words, the duration of the treatment (excluding any period during which the DIET material is encapsulated or fixed within a water-retaining material before being exposed to ambient processing temperatures) can be approximately 5 to 65 days, such as 10 to 50 days, 20 to 45 days, 30 to 40 days, or 35 to 40 days. For example, in the case of DIET being leaf Virginia tobacco, the treatment duration can be 35 to 45 days. For example, in the case of DIET being a blend of leaf Virginia tobacco and leaf Burley tobacco, the treatment duration can be 30 to 40 days.

[0107] In other embodiments, the DIET material is exposed to ambient processing temperatures exceeding 45°C (or any ambient processing temperature disclosed herein) for approximately 30 to 65 days, such as approximately 40 to 50 days or approximately 43 to 48 days. In other words, the duration of treatment (excluding any period during which the DIET material is encapsulated or fixed within a water-retaining material before exposure to ambient processing temperatures) can be approximately 30 to 65 days, such as approximately 40 to 50 days or approximately 43 to 48 days. Increasing the duration of treatment can increase the amount of Maillard reaction products, thereby providing a more concentrated flavor profile of the treated DIET.

[0108] Compared to embodiments of DIET material at lower temperatures, embodiments of DIET material at higher temperatures may require a shorter process period.

[0109] In other embodiments, the method involves processing the DIET material until its temperature reaches a target temperature, followed by cooling the tobacco material. This cooling can be achieved by removing the DIET material from the processing area, which is being maintained at a high temperature. In some embodiments, the target temperature is 60°C, 61°C, 62°C, 63°C, 64°C, 65°C, 66°C, 67°C, 68°C, 69°C, or 70°C. In some embodiments, the target temperature is in the range of 62 to 67°C. The target temperature may differ for different types of tobacco.

[0110] Following the treatment methods described herein, such as after exposing tobacco to ambient processing temperatures for any of the treatment durations described above, the DIET may be allowed to settle for a period of time. During this settling period, the DIET is typically kept encapsulated or secured within a water-retaining material.

[0111] This stabilization period can be initiated by removing the DIET material from the processing area that is being maintained at a high temperature. For example, the DIET material can be transported to a different processing area at a lower temperature, which may be about 30 °C or lower (such as from about 18 °C to about 30 °C, or from about 20 °C to about 25 °C, for example about 22 °C).

[0112] During the stabilization period, the temperature of DIET is gradually reduced, typically to about 30°C or lower (e.g., about 18°C ​​to about 30°C, or about 20°C to about 25°C, for example, about 22°C). After the processing, the moisture content of the periphery (or exterior or surface) of the dry ice expanded tobacco body (such as a bundle) is generally higher than the moisture content of the center (or core) of the dry ice expanded tobacco body. During the stabilization period, moisture from the peripheral dry ice expanded tobacco can be reabsorbed by the dry ice expanded tobacco in the center / core.

[0113] In other words, after the processing method, moisture is typically unevenly distributed throughout the batch of treated dry ice expanded tobacco, with the dry ice expanded tobacco at the periphery of the batch having a higher moisture content than that at the center (or core) of the batch. During the stabilization period, the moisture can become evenly distributed throughout the batch of treated tobacco material. This helps prevent microbial growth in the treated dry ice expanded tobacco at the periphery of the batch, thereby reducing waste and improving the shelf life of the treated dry ice expanded tobacco.

[0114] The moisture content of DIET after the stabilization period may be between about 10% and about 18%, or optionally between about 10% and about 15.5%, or optionally between about 10.5% and about 15%, such as between about 11% and about 14%.

[0115] The duration of the stabilization period can be at least 15 days, such as at least 30 days. For example, the stabilization period can be from 15 to 75 days, such as 20 to 60 days or 30 to 45 days. Typically, the stabilization period is about 40 days.

[0116] When the processing is carried out in a storage container, such as a cardboard box, as described above, the stabilization period also allows the storage container to regain the rigidity that was reduced during the processing. This can facilitate subsequent handling and transportation of tobacco materials processed with dry ice expansion.

[0117] The inventors have discovered that the processing methods described herein may result in the formation of hard lumps (also referred to as clumps or pads) of DIET tobacco. These lumps may also form during the stabilization period as the temperature of the DIET-treated tobacco gradually decreases. Such lumps may need to be removed before the DIET-treated tobacco can be used in products such as combustible aerosol supply systems and / or their components. Furthermore, the inventors have identified that such lumps do not form when processing other forms of tobacco to become DIET, such as when processing leaf tobacco that has not yet undergone dry ice expansion. Not wishing to be limited by theory, the inventors believe that the lumps form due to the compressible or fluffy nature of dry ice-expanded tobacco. During the temperature-increasing processing of dry ice-expanded tobacco, the dry ice-expanded tobacco material located on top of the moisture-retaining material may compress the dry ice-expanded tobacco material below it, resulting in the formation of compacted tobacco layers or lumps in the lower part of the body of the treated dry ice-expanded tobacco or in the batch.

[0118] In a particular embodiment, following the processing method described herein, such as after exposing tobacco to ambient processing temperatures for the duration of the aforementioned processing, the method also includes one or more steps of breaking up any tobacco material clumps formed during the DIET processing. For example, the method may also include applying one or more shear forces to the tobacco material clumps and / or chopping the tobacco clumps.

[0119] The method can also be carried out manually, for example by using hands or manual tools (such as hammers, mallets, rods, etc.) to break up the lumps of tobacco material formed during DIET processing. Alternatively, the method can be carried out mechanically, for example as part of a production line.

[0120] In a particular embodiment, the method may further include passing the treated DIET through one or more rollers to break up any tobacco clumps in the treated DIET. In a particular embodiment, each of the one or more rollers includes a plurality of teeth, spikes, and / or protrusions on its surface. In a particular embodiment, the one or more rollers may be one or more combing rollers. The treated dry ice expanded tobacco is typically spread on a conveyor member, such as a conveyor belt, which is assembled to transport the treated DIET toward the rollers. The conveyor member and the one or more rollers may be configured to cause the treated dry ice expanded tobacco to fall or drop from the one or more rollers during use, thereby breaking up one or more tobacco clumps. For example, the plurality of conveyor members may be staggered such that there are one or more drops between them, and the one or more rollers may be configured in one or more drops.

[0121] In some embodiments, the method may include multiple sequential rolling steps. In a particular embodiment, one or more rolling steps continue until the wt% of tobacco clumps reaches a target value, or until the wt% of tobacco material having a particle size of 2.5 cm or less reaches a target value. The target value may be in any range listed below, such as tobacco clumps in the range of less than or equal to 15 wt%, or DIET having a particle size of 2.5 cm or less in the range of 85 wt% or greater.

[0122] In some embodiments, the method may also include a first rolling step using one or more first rollers and a second rolling step using one or more second rollers, the first roller having a plurality of first teeth, first spikes and / or first protrusions on its surface, and the second roller having a plurality of second teeth, second spikes and / or second protrusions on its surface, wherein the spacing between the plurality of first teeth, first spikes and / or first protrusions is greater than the spacing between the plurality of second teeth, second spikes and / or second protrusions. In the first rolling step, any tobacco lumps are broken into smaller lumps having a first particle size. The smaller tobacco lumps provided by the first rolling step are then broken into even smaller lumps having a smaller second particle size in the second rolling step. In certain embodiments, the first rolling step occurs once, and the second rolling step occurs two or more times. Performing the second rolling step multiple times can further reduce the wt% of tobacco lumps processed in the DIET. In a particular implementation, the second rolling step occurs twice, that is, the DIET is processed and passes through one or more second rolls twice.

[0123] As used herein, wt% of tobacco clumps refers to the percentage by mass of the treated DIET material that did not pass through a sieve with a pore size of 2.5 cm x 2.5 cm, relative to the total mass of the treated DIET material. In some embodiments, one or more steps of crushing any tobacco material clumps provide DIET containing less than or equal to 15 wt% (i.e., 0-15 wt%) of tobacco clumps, optionally less than or equal to 10 wt% of tobacco clumps, such as less than or equal to 5 wt% of tobacco clumps, less than or equal to 2 wt% of tobacco clumps, or less than or equal to 1 wt% of tobacco clumps.

[0124] In other words, one or more steps of crushing any tobacco material lumps can provide DIET, wherein 85 wt% or more (i.e., 85-100 wt%) of the DIET has a particle size of 2.5 cm or less, and optionally 90 wt% or more, such as 95 wt% or more, 98 wt% or more, 99 wt% or more of the DIET has a particle size of 2.5 cm or less. In this context, wt% of the treated DIET material having a particle size of 2.5 cm or less represents the percentage by mass of the treated DIET material passing through a sieve with a pore size of 2.5 cm x 2.5 cm relative to the total mass of the treated DIET material.

[0125] When performing one or more steps of breaking up any lumps of tobacco material (e.g., when spreading treated tobacco through one or more rollers), the treated DIET can be cooled more rapidly and the stabilization period described above can be unexpectedly avoided without adversely affecting the fill power, moisture content, moisture distribution, and flavor profile of the treated DIET. For example, the temperature of the DIET can be reduced to about 30 °C or lower (e.g., from about 18 °C to about 30 °C, or from about 20 °C to about 25 °C, for example, about 22 °C) over a period of 0.05 to 3 hours, optionally 0.1 to 2 hours, such as from 0.15 to 1 hour or from 0.2 to 0.7 hours. Avoiding the stabilization period can significantly shorten the total processing time of the DIET tobacco material.

[0126] Another aspect of the present invention relates to a method comprising crushing any tobacco clumps produced by the method described in the present invention in a processed DIET material. The above-described embodiments are applicable in comparison to this aspect of the present invention.

[0127] The filling value (also referred to herein as fill value) is a measure of the volume occupied by a given mass of tobacco when a given pressure is applied at a given moisture content. In other words, the fill value is a measure of the ability of a material to occupy a specific volume at a given moisture content. In this invention, the fill value can be determined by test method A as disclosed in the following example paragraph.

[0128] As explained above, the high filling value of dry ice-expanded tobacco is maintained during the method. The filling value of dry ice-expanded tobacco may even increase during the method. In some embodiments, the filling value of DIET treated at 13.5% moisture content is at least 6 cm³ / g, such as at least 6.5 cm³ / g or at least 7 cm³ / g. In some embodiments, the filling value of DIET treated at 13.5% moisture content is 6 to 10 cm³ / g, such as 6.5 to 9 cm³ / g or 7 to 8 cm³ / g.

[0129] In some embodiments, the filling value of untreated DIET at a moisture content of 13.5% is at least 6 cm³ / g, such as at least 6.5 cm³ / g or at least 7 cm³ / g. In some embodiments, the filling value of untreated DIET at a moisture content of 13.5% is 6 to 10 cm³ / g, such as 6.5 to 9 cm³ / g or 7 to 8 cm³ / g.

[0130] It has been found that at least one change in the sensory properties of tobacco materials is the result of a reduction in negative characteristics, such as a reduction in tobacco material components with unpleasant tastes or irritating effects. In some embodiments, sensory properties are altered by increasing positive properties, for example by increasing or introducing components that contribute positively to sensory properties, such as components with pleasant tastes.

[0131] In some embodiments, the tobacco material is treated to give it the desired sensory properties that can be reliably and in relatively large quantities produced. In some embodiments, the method is a batch method.

[0132] After the DIET has been cultivated for the required time, the tobacco can be cooled while retaining the water-retaining material.

[0133] For treated DIET materials, sufficiently mild method parameters are used to maintain some or all of their physical properties. For example, the DIET material remains substantially intact after treatment, allowing it to be handled and / or processed for inclusion in tobacco-containing products, such as smoking objects. This allows the treated DIET material to be processed according to standard methods.

[0134] Treated DIET material may have a different color than untreated DIET material. In some embodiments, the DIET material is darker in color than the untreated tobacco material.

[0135] Importantly, treated DIET materials possess sensory properties that are acceptable and / or desired by consumers. Therefore, tobacco materials with desired sensory properties can be manufactured by treating DIET under specific conditions without the need to add one or more other chemicals, which would cause harm and / or increase costs. Furthermore, treated DIET does not require additional processing steps to remove other chemicals, thus avoiding additional costs or time for tobacco processing methods.

[0136] The sensory properties of treated tobacco material can be developed when the tobacco material is immobilized in a water-retaining material, during which the components in the tobacco material undergo chemical changes and modifications to impart the desired sensory characteristics to the final product. In some embodiments, the treated tobacco material may have a sweet and spicy and / or rich aroma. In some embodiments, the treated tobacco material may not have a dry and / or bitter taste.

[0137] In some embodiments, the chemical composition of the treated DIET material differs significantly from that of the untreated DIET material. For example, as shown in the examples, in some embodiments, most of the sugars in the treated DIET material are converted and the concentrations of nicotine and total amino acids are reduced.

[0138] Not limited to theory, it is generally believed that at least part of the changes in the content of these compounds are attributable to the Maillard reaction that occurs during the method. Caramelization may also occur during the method, which can lead to a decrease in the content of reducing sugars and non-reducing sugars.

[0139] In addition, in some embodiments, the content of various amino acid components was found to be significantly reduced.

[0140] Therefore, this method can lead to an increase in at least one product of the Maillard reaction in the treated DIET material. The products of the Maillard reaction include: 2,6-deoxyfructazine; 2,5-deoxyfructazine; 5-acetyl-2,3-dihydro-1H-pyrrolizine; 2,3-dihydro-5-methyl-1H-pyrrolizine-7-carboxaldehyde; 1,2,3,4,5,6-hexahydro-5-(1-hydroxyethylidene)-7H-cyclopentan[b]pyridin-7-one; 1-(1-pyrrolidinyl)-2-butanone; 1-(2,3-dihydro-1H- Pyrrolizin-5-yl)-1,4-pentanediol; 2,3,4,5,6,7-hexahydro-cyclopentazopyridone-8(1H)-one; 5-(2-furanyl)-1,2,3,4,5,6-hexahydro-7H-cyclopentazopyridone-7-one; 4-(2-furanylmethylene)-3,4-dihydro-2H-pyrrole; and 1,2,3,4,5,6-hexahydro-7H-cyclopentazopyridone-7-one. Increased carotenoid concentration can also indicate that the Maillard reaction has occurred.

[0141] In some embodiments, the treated DIET material may contain a reduced nicotine level compared to untreated tobacco material, as shown in the examples. Nicotine is known to have a bitter taste, therefore reducing the content of this compound can have a positive effect on the taste and aroma of the treated tobacco material.

[0142] To manufacture DIET materials with desired sensory properties, it is not necessary to add other substances to tobacco to provide or enhance its sensory properties. Such substances include flavoring agents and / or aromatic components.

[0143] As used herein, the terms "flavoring agent" and "seasoning agent" refer to materials permitted by local regulations for use in products intended to create a desired flavor or aroma for adult consumers. They may include extracts (e.g., licorice, hydrangea, magnolia leaf, chamomile, fenugreek, clove, menthol, Japanese mint, fennel, cinnamon, herbs, holly, cherry, berries, peach, apple, Drambuie whisky, bourbon whisky, Scotch whisky, whisky, spearmint, peppermint, lavender, white cardamom, celery, calomel, nutmeg, sandalwood, bergamot, geranium, honey essence, rose oil, vanilla, lemon oil, orange oil). Ingredients may include: cinnamon, caraway, cognac, jasmine, ylang-ylang, sage, fennel, allspice, ginger, star anise, coriander, coffee, or peppermint oil from any species of the peppermint genus; flavor enhancers; bitter taste receptor blockers; sensory receptor activators or activators; sugars and / or artificial sweeteners (e.g., sucralose, acesulfame potassium, aspartame, saccharin, saccharin, saccharin, lactose, sucrose, glucose, fructose, sorbitol, or mannitol); and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners. These may be analogues, synthetic or natural ingredients, or blends thereof. They may be in any suitable form, such as oil, liquid, or powder.

[0144] The treated DIET material can be incorporated into a combustible aerosol delivery system, which may also be referred to as a smoking object in this document.

[0145] As used herein, the term “delivery system” is intended to encompass systems that deliver at least one substance to a user, including combustible aerosol delivery systems such as cigarettes, cigarettes, cigars and tobacco (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokeable materials) for pipes or for rolling or making cigarettes.

[0146] According to this disclosure, a "flammable" aerosol supply system is a system that, during use, burns or roasts the aerosol generating material of the aerosol supply system (or its components) to facilitate the delivery of at least one substance to the user.

[0147] In some embodiments, the combustible aerosol supply system is selected from the group consisting of cigarettes, cigarillos, or cigars.

[0148] In some embodiments, this disclosure relates to components for use in combustible aerosol supply systems, such as filters, filter rods, filter sections, tobacco sticks, wood chips, aerosol modifier release components, such as capsules, threads or beads, or paper, such as plug wrap, tipping paper, or cigarette paper.

[0149] The treated DIET material can be used in self-rolled tobacco and / or pipe tobacco.

[0150] The treated DIET material may be blended with one or more tobacco materials before being incorporated into a smoking object or used in self-rolled or pipe tobacco.

[0151] In some embodiments, tobacco extracts can be created from DIET materials that have undergone the processing described herein. In some embodiments, the extract may be a liquid, such as an aqueous extract. In other embodiments, the extract may be produced by supercritical fluid extraction.

[0152] Therefore, one approach provides a method for producing tobacco extracts from DIET tobacco materials, the tobacco extracts having been processed by the method described herein.

[0153] In some embodiments, the extract can be used in a combustible aerosol supply system. For example, the extract can be added to tobacco or another material used for combustion in a smoking object.

[0154] As explained above, the advantageous changes in the sensory properties of DIET tobacco provided by the method herein mean that treated tobacco can be added in higher quantities than untreated DIET tobacco to tobacco blends (e.g., for use in smoking articles), or to combustible aerosol delivery systems or their components, without impairing the sensory properties of the tobacco blends, combustible aerosol delivery systems, or their components. Therefore, the method described herein may further include incorporating treated tobacco into the blend.

[0155] In some embodiments, the tobacco blend may contain treated tobacco in an amount ranging from 1 to 60 wt%, such as from 5 to 60 wt%, from 10 to 55 wt%, from 15 to 50 wt%, or from 20 to 45 wt%, relative to the total weight of the blend.

[0156] The blend may further comprise one or more other tobacco varieties. These other tobacco varieties may include one or more Virginia tobaccos, one or more Burley tobaccos, one or more Oriental tobaccos, and combinations thereof. Dry ice-treated expanded tobacco can enhance rich flavor characteristics, allowing the blend to provide a sufficiently rich flavor profile while having a lower Burley tobacco varietal inclusion.

[0157] One or more aerosol-forming materials may be added to the DIET provided by the method described herein to provide a smokeable material. The aerosol-forming material may contain one or more components capable of forming aerosols. In some embodiments, the aerosol-forming material may contain one or more of the following: glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butanediol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl octanoate, triethyl citrate, glyceryl triacetate, a mixture of glyceryl diacetate, methyl benzoate, phenylmethyl benzoate, glyceryl tribocate, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0158] Smokeable materials supplied for use in combustible aerosol supply systems may typically contain a lower amount of aerosol forming agent material than aerosol generating materials supplied for use in non-combustible aerosol supply systems. For example, smokeable materials containing DIET may contain aerosol forming agent in a total amount from 0 to 20 wt% on a dry weight basis (DWB), such as 0.1 to 10 wt% (DWB), 0.25 to less than 10 wt% (DWB), such as 0.5 to 9 wt% (DWB), or 1 to 5 wt% (DWB). Smokeable materials may contain an amount of aerosol forming agent of less than 20 wt% (DWB), less than 10 wt% (DWB), less than 9 wt% (DWB), or less than 5 wt% (DWB). In these embodiments, dry weight (DWB) refers to all smokeable materials other than any water, and may include components that are liquid at room temperature and pressure, such as glycerin.

[0159] The DIET provided by the methods described herein, or a smokeable material containing the DIET (e.g., in combination with an aerosol-forming agent material), may be blended with other components to provide a blend, as described above. The total amount of aerosol-forming agent present in the blend may range from 0 to less than 4 wt% (DWB), such as 0.1 to 2 wt%. In these embodiments, dry weight (DWB) refers to all blends except any water, and may include components that are liquid at room temperature and pressure, such as glycerol.

[0160] To solve various problems and improve the technology, the entire system disclosed herein is illustrated by various examples, wherein the claimed invention is an executable method for processing tobacco. The advantages and features of this disclosure are only representative samples of embodiments and are not exhaustively listed and / or are not unique. These are listed only to assist in understanding and teaching the claimed features. It should be understood that the advantages, embodiments, examples, functions, features, structures and / or other embodiments of this disclosure should not be considered as limitations on the disclosure as defined in the claims or on those equivalent to the claims. Other embodiments and modifications may be used without departing from the scope and / or spirit of this disclosure. Various embodiments may suitably include, consist of, or substantially consist of various combinations of the disclosed elements, components, features, parts, steps, components, etc. Furthermore, this disclosure includes other inventions not currently claimed but which may be claimed in the future. Example Test Method A

[0161] In the following embodiments, the tobacco filling value is measured according to the following method.

[0162] A 15 g sample of tobacco material was placed in the 60 mm diameter cylinder of the hydrometer, and then the tobacco material was compressed for 30 seconds with a piston of 2.90 ± 0.03 kg. The height of the piston in the hydrometer and the moisture content of the sample were measured. The filling value of the sample was calculated according to the following formula.

[0163] Use Formula 1 to determine the volume occupied by the tobacco material during compression: Formula 1 r = radius of the cylinder (cm) h = measured height (mm)

[0164] Subsequently, the filling value is determined using the measured volume and mass of the tobacco material according to Equation 2: Equation 2

[0165] Use Formula 3 to correct the filling value to take into account its moisture content: Formula 3 FV0 = Filling value at moisture content Mo% FV = Filling value measured at moisture content M% (cm3 / 10g) Mo = 13.5% (target moisture content) M = Actual moisture content of tobacco material (%) 0.8 = Constant

[0166] Moisture content (oven volatiles) is measured as the mass reduction of the sample when it is dried in a forced-ventilation oven at a temperature adjusted to 110°C ± 1°C for three hours ± 0.5 minutes. After drying, the sample is allowed to cool to room temperature in a desiccator for approximately 30 minutes to allow it to cool. Example 1: Production of DIET Tobacco

[0167] The leaves of Virginia and Burley tobacco are processed, blended, cut and dried.

[0168] The tobacco material was then formed into dry ice expanded tobacco. Cut Virginia and cut Burley tobacco were moistened. For the following sample R, the Virginia and Burley tobacco were then blended. The moistened and selectively blended tobacco material had a moisture content of approximately 26%. The tobacco material was then fed into an impregnation machine container and then pressurized with carbon dioxide at a temperature of -20 °C for approximately 6 minutes. The impregnated tobacco material was fed into a sublimator, and then the pressure was reduced to solidify the liquid carbon dioxide. The impregnated tobacco material was then heated in an airflow at a temperature of 330 °C, causing the moisture and carbon dioxide in the tobacco material to evaporate rapidly.

[0169] Sample A below is dry ice-expanded Virginia tobacco leaves. Sample R below is a 1:1 w / w blend of dry ice-expanded Virginia and Burley tobacco leaves. Production of expanded stem tobacco

[0170] The tobacco stems obtained from threshing fresh leaves are moistened to a moisture content of 25-35%, and then cut into widths of 25-28 CPI. The cut stems are then subjected to steam treatment involving heating to 180-250°C for 15 seconds to 3 minutes, causing the water within the tobacco cells to evaporate and the tobacco to expand. After steam treatment, the stem tobacco has a moisture content of 13-14%. Tobacco Processing

[0171] 80 kg of DIET tobacco was wrapped in a polyethylene liner (Polyliner®) and packaged in a single-walled box with external dimensions of 0.835 m x 1.120 m x 0.765 m. It was then left to stand for at least 30 days before exposure to ambient processing conditions of 60°C and 60% relative humidity for 35, 37, or 39 days (for sample A) or 35 days (for sample R). The packing density of the tobacco prior to treatment was approximately 123 kg / m³.

[0172] 70 kg of expanded stems were wrapped in a polyethylene liner (Polyliner®), packed in a C-48 box, and left to stand for at least 30 days before exposure to ambient processing conditions of 60°C and 60% relative humidity for 14, 21, or 28 days. Taste evaluation.

[0173] Cigarettes containing untreated DIET, untreated expanded stems, treated DIET, or treated expanded stems were produced. Blind smoking tests were then conducted by expert smokers. No significant difference was observed between treated expanded stems and untreated expanded stems. However, compared to untreated DIET, an increase in the spiciness aroma of treated DIET (both Sample A and Sample R) was observed. An increase in the tannin aroma of treated DIET (Sample R) was also observed compared to the untreated control group.

[0174] Therefore, unlike other forms of expanded tobacco (expanded stems), the flavor properties of DIET tobacco are improved by the treatment rather than intended. Analysis of filler values

[0175] The fill value of DIET tobacco was measured before and after treatment. This value was corrected to adjust for moisture content; the reference value is 13.5% moisture content. Table 1: Sample A of fill values ​​for treated and untreated DIET tobacco. Processing duration (days) Filler value (cm) at 13.5% moisture 3 / g) 0 (Control Group) 7.019 35 7.242 37 7.355 39 7.445 Sample R Processing duration (days) Filler value (cm) at 13.5% moisture 3 / g) Batch 1 0 (Control Group) 7.55 Batch 1 35 7.832 Batch 2 0 (Control Group) 7.134 Batch 2 35 7.674 Batch 3 0 (Control Group) 7.358 Batch 3 35 7.445 Analysis of nicotine

[0176] The nicotine content of treated tobacco was analyzed using a colorimetric method (continuous flow analysis on an AutoAnalyzer 3 machine). The results are presented in Table 2. Table 2: Nicotine content of treated and untreated tobacco samples A Processing duration (days) Nicotine % (DWB) 0 (Control Group) 2.37 35 2.01 37 2.02 39 1.9 Sample R Processing duration (days) Nicotine % (DWB) Batch 1 0 (Control Group) 2.66 Batch 1 35 2.38 Batch 2 0 (Control Group) 2.722 Batch 2 35 2.436 Batch 3 0 (Control Group) 2.735 Batch 3 35 2.445

[0177] As can be seen from Table 2, the tobacco material contained a lower amount of nicotine after treatment compared to before treatment. Sugar content analysis.

[0178] A colorimetric method was used to determine the total sugar content of treated tobacco, including all reducing substances and sucrose. The colorimetric method was a continuous flow analysis using an Auto alyo 3 instrument. The results are presented in Table 3. Table 3: Sugar content of treated and untreated tobacco samples A Processing duration (days) Total sugar content % (DWB) 0 (Control Group) 16.2 35 6.5 37 6.4 39 5.3 Sample R Processing duration (days) Total sugar content % (DWB) Batch 1 0 (Control Group) 7.80 Batch 1 35 2.00 Batch 2 0 (Control Group) 6.6 Batch 2 35 2.1 Batch 3 0 (Control Group) 7.3 Batch 3 35 2

[0179] Table 3 shows that the tobacco contained less sugar after treatment compared to before treatment. Humidity analysis.

[0180] To support the theory that the sugar content in tobacco materials gradually decreases, the moisture content before and after processing was analyzed. Since the tobacco materials were coated with a water-retaining material, no moisture entered the tobacco materials from the external environment. Therefore, the observed increase in water / humidity after processing is believed to be due to the decrease in sugar content in the tobacco materials. Table 4: Moisture Analysis (Measured as Oven Volatile Matter (OV)) Sample A Processing duration (days) Moisture (%) 0 (Control Group) 12.33 35 14.9 37 14.56 39 13.16 Sample R Processing duration (days) Moisture (%) Batch 1 0 (Control Group) 11.96 Batch 1 35 13.55 Batch 2 0 (Control Group) 11.47 Batch 2 35 13.36 Batch 3 0 (Control Group) 12.48 Batch 3 35 13.05 Amino acid analysis

[0181] Analysis of treated tobacco using a Q-TOF (quadrupole time-of-flight) analyzer via ultra-high pressure liquid chromatography (UPLC) revealed a significant reduction in amino acid content, as indicated in Table 5 below. Table 5: Amino Acid Content Analysis Sample A Processing duration (days) Total amino acids (abundance / any unit) 0 (Control Group) 78.39 35 47.67 37 43.09 39 46.26 Sample R Processing duration (days) Total amino acids (abundance / any unit) Batch 1 0 (Control Group) 88.75 Batch 1 35 70.72 Batch 2 0 (Control Group) 89.05 Batch 2 35 64.34 Batch 3 0 (Control Group) 90.05 Batch 3 35 65.42 Analysis of carotenoids

[0182] Analysis of treated tobacco showed a significant increase in carotenoid content, as indicated in Table 6 below. Table 6: Analysis of Carotenoids in Sample A Processing duration (days) Carotenoids (abundance / any unit) 0 (Control Group) 22.01 35 38.42 37 37.78 39 36.53 Sample R Processing duration (days) Carotenoids (abundance / any unit) Batch 1 0 (Control Group) 21.01 Batch 1 35 35.80 Batch 2 0 (Control Group) 19.56 Batch 2 35 37.00 Batch 3 0 (Control Group) 17.98 Batch 3 35 34.20 Example 2

[0183] Virginia tobacco leaves were treated for 39 days using the method described for sample A in Example 1. After treatment, the temperature of the DIET tobacco was 64 °C. Subsequently, during a 40-day stabilization period, the tobacco temperature gradually decreased to 22 °C. Large clumps of tobacco were observed within the treated DIET material. The properties of the tobacco after the stabilization period are shown in the table below (Test 1).

[0184] After the stabilization period, DIET tobacco has a moisture content (OV) of 14% and a filling value of 6.8 cc / g. The proportion of tobacco that did not pass through a sieve with a pore size of 2.5 cm x 2.5 cm is 40 wt%.

[0185] In Test 2 below, the tobacco material is immediately conveyed after processing through a first set of carding rollers in the form of rollers, which includes a plurality of protruding rods from their surfaces, and then conveyed through a second set of carding rollers in the form of rollers, which also includes a plurality of protruding rods from their surfaces. The spacing between the protruding rods on the first set of carding rollers is greater than the spacing between the protruding rods on the second set of carding rollers. In Test 3 below, the tobacco material is conveyed a second time through the second set of carding rollers. In Test 4 below, the tobacco material is conveyed a third time through the second set of carding rollers. The cooling time for Tests 2-4 is 30 minutes or less. Figure 4 shows the processed DIET passing through a set of carding rollers. Test 1 Test 2 Test 3 Test 4 Temperature after 39 days of treatment 64 64 64 64 Temperature of tobacco after cooling twenty two twenty two twenty two twenty two Moisture content % (Measured as oven volatiles (OV)) 14 13.8 13.7 13.6 Fill value (cc / g) 6.8 6.8 6.8 6.7 Wt% of tobacco lumps 40 9 1 1 * Percentage of DIET material by mass that did not pass through a sieve with a aperture of 2.5 cm x 2.5 cm.

[0186] Cigarettes containing untreated DIET, untreated expanded stems, treated DIET, or treated expanded stems were produced. A blind smoking test was then conducted by expert smokers. The expert smoker panel determined that there was no significant difference in the sensory profile between cigarettes containing tobacco produced in Tests 2, 3, and 4 and the control group sample (cigarettes containing tobacco produced in Test 1). [Simplified Explanation of the Diagram]

[0015] For illustrative purposes only, several embodiments of the present invention are described below with reference to the accompanying drawings, in which: Figure 1 is a flowchart of a method for manufacturing dry ice expanded tobacco; Figure 2 shows cross-sections of tobacco leaves before (top) and after (bottom) dry ice expansion. The scale bars (center, bottom) of each image correspond to a distance of 100 micrometers. Figure 3 is a flowchart of a method for manufacturing expanded stem tobacco. Figure 4 is a photograph of processed DIET passing through a set of combing rollers (doffer).

Claims

1. A method for producing dry ice expanded tobacco (DIET) for use in a combustible aerosol delivery system, the method comprising exposing dry ice expanded tobacco encapsulated in a water-retaining material to an ambient processing temperature exceeding 45°C, wherein the tobacco material has a packing density of 60 to 160 kg / m³ at the start of the method and a moisture content of about 10% to 23% before and during processing.

2. The method of claim 1, wherein the tobacco material has a packing density of 90 to 135 kg / m³ at the start of the method.

3. The method of claim 2, wherein the tobacco material has a packing density of 100 to 130 kg / m³ at the start of the method.

4. The method of any of the preceding claims, wherein the dry ice-expanded tobacco comprises leaf tobacco.

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

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

7. The method of any of the preceding claims, wherein the treated tobacco material has a filling value of 6 cm³ / g at 13.5% moisture content.

8. The method of any of the preceding claims, wherein the method comprises providing the dry ice-expanded tobacco by dry ice expansion of a tobacco material before exposing the dry ice-expanded tobacco to the ambient processing temperature.

9. The method of any of the preceding claims, wherein the tobacco material has a moisture content between about 10% and 15.5% before and during treatment.

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

11. The method of any of the preceding claims, wherein the microbial content of the treated tobacco material is lower than that of the untreated tobacco material.

12. The method of any of the preceding claims, wherein the temperature of the tobacco material reaches the ambient processing temperature in about 4 to 10 days.

13. The method of any of the preceding claims, wherein the temperature of the tobacco material reaches a second temperature higher than the ambient processing temperature, such that the second temperature exceeds the ambient processing temperature by at least 2°C.

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

15. The method of any of the preceding claims, wherein the method causes a reduction in the content of at least one of compounds selected from the group consisting of nicotine, reducing sugars, non-reducing sugars and amino acids in the treated tobacco material.

16. The method of any of the preceding claims, wherein the method substantially does not involve fermentation.

17. The method of any of the preceding claims, wherein the ambient processing humidity is between about 50-500 g water / m³ for an ambient processing temperature of about 100°C or more, between 50-340 g water / m³ for an ambient processing temperature of about 90°C, between 50-230 g water / m³ for an ambient processing temperature of about 80°C, between 50-160 g water / m³ for an ambient processing temperature of about 70°C, between 50-110 g water / m³ for an ambient processing temperature of about 60°C, or between 40-80 g water / m³ for an ambient processing temperature of about 55°C.

18. The method of any of the preceding claims, wherein the water-retaining material is wrapped around the tobacco material, such as wherein the water-retaining material comprises a flexible polymeric material, such as wherein the flexible polymeric material comprises polyethylene.

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

20. The method of any of the preceding claims, further comprising breaking up any clumps of tobacco material formed during the processing of the dry ice-expanded tobacco.

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

22. The method of any of the preceding claims, wherein during the method, the dry ice expanded tobacco reaches a temperature equal to or higher than the ambient processing temperature ("TX") and wherein the dry ice expanded tobacco is subsequently cooled from the temperature ("TX") to 30 °C or lower, such as from about 18 °C to about 30 °C, or from about 20 °C to about 25 °C, or from about 22 °C, over a period of 0.05 to 3 hours, such as from 0.1 to 2 hours, such as from 0.15 to 1 hour, or from 0.2 to 0.7 hours.

23. A type of dry ice-expanded tobacco, which can be obtained by any of the methods described in the preceding claims.

24. A component for use in a combustible aerosol supply system, the component comprising the dry ice-treated expanded tobacco material as claimed in claim 23.

25. An article for use in a flammable aerosol supply system, the article comprising the components as claimed in claim 24.

26. A combustible aerosol supply system comprising processed dry ice expanded tobacco material as claimed in claim 23, components as claimed in claim 24, or articles as claimed in claim 25.

27. Use of the dry ice-treated expanded tobacco material as claimed in claim 23, for manufacturing a component for use in a combustible aerosol supply system.

28. The component of claim 24, the object of claim 25, the combustible aerosol supply system of claim 26, or the use of claim 27, wherein the combustible aerosol supply system is a cigarette, a cigarette, or a cigar.

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