Method for producing reconstituted tobacco sheet

Abstract

Provided is a method for producing a reconstituted pressure-molded tobacco sheet. This production method has: a first step for loading water and a binder into a mixer and mixing to dilute the binder; a second step, after the first step, for loading a first liquid raw material and a powder raw material, which contains at least tobacco, into the mixer and mixing with the diluted binder; and a molding step for molding the raw material mixed in the second step into a pressure-molded sheet.

Description

TECHNICAL FIELD

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

[0002] Rolling methods, casting (slurry) methods, and sheet-forming methods are conventionally known methods for producing reconstituted tobacco sheets. These manufacturing methods are selected depending on the amount of moisture contained in the reconstituted tobacco raw material. The devices for producing reconstituted tobacco sheets that are employed in these methods of production are also different from each other.

[0003] Rolling methods are known to be particularly suitable for reconstituted tobacco raw materials that contain up to 50% by volume of moisture. In rolling methods, kneaded reconstituted tobacco raw materials are rolled and formed by means of rotating rollers, the thickness is adjusted, and the material is then dried in a separately provided dryer.

[0004] Casting (slurry) methods are known to be particularly suitable for reconstituted tobacco raw materials that contain 50% by volume or more of moisture. In casting (slurry) methods, a reconstituted tobacco raw material fluid is continuously spread onto a rotating drum or belt conveyor, is leveled to a desired thickness with a member called a blade, is then released from the rotating drum or the belt conveyor, and is dried in a separately provided dryer.

[0005] Sheet-forming methods are known to be particularly suitable for reconstituted tobacco raw materials that contain 80% by volume or more of moisture. In sheet-forming methods, a reconstituted tobacco raw material fluid is continuously spread onto a liquid-permeable belt conveyor, moisture is removed and the desired thickness is achieved by means of squeeze rolls, and the material is then dried in a separately provided dryer.

[0006] In contrast to these production methods, which are selected depending on the moisture content, there are a known device and method for producing a reconstituted tobacco sheet that allow a reconstituted tobacco sheet of uniform thickness to be obtained via a simple production process, regardless of the amount of moisture contained in the reconstituted tobacco raw material (see PTL 1).CITATION LISTPatent Literature

[0007] PTL 1: International Publication No. 2022 / 019027SUMMARY OF INVENTIONTechnical Problem

[0008] In cases where reconstituted tobacco sheets are pressure-molded, such as in the method disclosed in PTL 1 or in rolling methods, no consideration has been given to methods for producing reconstituted pressure-molded tobacco raw materials.

[0009] An object of the present invention is to provide a novel method for producing a reconstituted pressure-molded tobacco sheet.Solution to Problem

[0010] A first aspect provides a method for producing a reconstituted pressure-molded tobacco sheet. The production method comprises: a first step in which two or more powdered raw materials comprising at least tobacco are introduced into and mixed in a mixer; a second step in which a first liquid raw material is introduced, after the first step, into the mixer and mixed with the two or more powdered raw materials; and a molding step in which the raw materials mixed in the second step are molded into a pressure-molded sheet.

[0011] According to the first aspect, the two or more powdered raw materials are mixed in the first step before the powdered raw material and the first liquid raw material are mixed, thus allowing the two or more powdered raw materials to be thoroughly mixed.

[0012] The two or more powdered raw materials may comprise tobacco, a binder, and an additive.

[0013] In this case, the powdered raw material and the first liquid raw material are mixed, thereby allowing tobacco raw materials in which the viscosity has been increased by the binder to be produced. The additive may comprise, 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 additive is included in the powdered raw material to allow the strength of the tobacco sheet to be increased or to allow flavor to be provided.

[0014] The first liquid raw material may comprise an aerosol source, water, and an additive.

[0015] In this case, the powdered raw material and the first liquid raw material are mixed, thereby allowing tobacco raw materials in which a greater amount of aerosol is generated to be produced. The aerosol source may comprise, for example, one or more selected from the group consisting of glycerol and propylene glycol. The additive may also comprise, for example, liquid flavoring. The liquid flavoring is included in the liquid raw material to allow the tobacco sheet to be flavored.

[0016] The second step may comprise introducing 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 additive contained in the first liquid raw material are pre-mixed, thus allowing the powdered raw material and the first liquid raw material to be more uniformly mixed.

[0018] The production method may comprise: a step in which the raw material mixed in the second step is fed to an extruder; and a step in which a second liquid raw material is furthermore added to the raw material fed to the extruder.

[0019] The raw material must have moisture suitable for the extrusion process in order for the raw material to be extruded in an extruder. On the other hand, a raw material that is moist enough to be extruded in an extruder will be highly adhesive, and will thus be difficult to handle outside the extruder. Adding a second liquid raw material to the raw material in the extruder will therefore allow the moisture of the raw material to be adjusted in the extruder, and thus allow the amount of the first liquid raw material that is mixed in the mixer to be lowered. As a result, the raw material in the mixer can be prevented from becoming highly adhesive, thus allowing the raw material to be easily handled when the raw material is fed from the mixer to the extruder.

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

[0021] This will allow the amount of the first liquid raw material that is mixed in the mixer to be lowered. As a result, the raw material in the mixer can be prevented from becoming highly adhesive, thus allowing the raw material to be easily handled when the raw material is fed from the mixer to the extruder. The second liquid raw material may include one or more selected from the group consisting of water, glycerol, propylene glycol, binder solution, and liquid flavoring.

[0022] The molding step may comprise: a step in which the raw material mixed in the second step is extruded by means of an extruder into a die; and a step in which the raw material is extruded from the die into the form of a sheet.

[0023] The molding step may comprise: a step in which the raw material mixed in the second step is extruded by means of an extruder; and a step in which the raw material extruded from the extruder is formed into a sheet by at least a pair of vertically facing rolling rollers.

[0024] The molding step may comprise: a step in which the raw material mixed in the second step is extruded by means of an extruder; and a step in which the raw material extruded from the extruder is formed into a sheet by being passed between two or more horizontally adjacent rolling rollers.

[0025] A second aspect provides a method for producing a reconstituted pressure-molded tobacco sheet. The production method comprises: a first step in which a first liquid raw material is introduced into a mixer; a second step in which a powdered raw material comprising at least tobacco is introduced, after the first step, into the mixer and mixed with the first liquid raw material; and a molding step in which the raw materials mixed in the second step are molded into a pressure-molded sheet.

[0026] According to the second aspect, the powdered raw material is mixed with the first liquid raw material, thus making it possible to prevent the powdered raw material from becoming lumpy and allowing the raw materials to be more uniformly mixed.

[0027] The powdered raw material may include tobacco, a binder, and an additive.

[0028] In this case, the powdered raw material and the first liquid raw material are mixed, thereby allowing tobacco raw materials in which the viscosity has been increased by the binder to be produced. The additive may comprise, 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 additive is included in the powdered raw material to allow the strength of the tobacco sheet to be increased or to allow flavor to be provided.

[0029] The second step may comprise separately introducing and mixing each of the tobacco, the binder, and the additive with the first liquid raw material in the mixer.

[0030] In this case, the powdered raw materials are separately mixed with the first liquid raw material, thus making it possible to further prevent the powdered raw material from becoming lumpy and allowing the raw materials to be more uniformly mixed.

[0031] The first liquid raw material may comprise an aerosol source, water, and an additive.

[0032] In this case, the powdered raw material and the first liquid raw material are mixed, thereby allowing tobacco raw materials in which a greater amount of aerosol is generated to be produced. The aerosol source may comprise, for example, one or more selected from the group consisting of glycerol and propylene glycol. The additive may also comprise, for example, liquid flavoring. The liquid flavoring is included in the liquid raw material to allow the tobacco sheet to be flavored.

[0033] The production method may comprise: a step in which the raw material mixed in the second step is fed to an extruder; and a step in which a second liquid raw material is furthermore added to the raw material fed to the extruder.

[0034] The raw material must have moisture suitable for the extrusion process in order for the raw material to be extruded in an extruder. On the other hand, a raw material that is moist enough to be extruded in an extruder will be highly adhesive, and will thus be difficult to handle outside the extruder. Adding a second liquid raw material to the raw material in the extruder will therefore allow the moisture of the raw material to be adjusted in the extruder, and thus allow the amount of the first liquid raw material that is mixed in the mixer to be lowered. As a result, the raw material in the mixer can be prevented from becoming highly adhesive, thus allowing the raw material to be easily handled when the raw material is fed from the mixer to the extruder.

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

[0036] This will allow the amount of the first liquid raw material that is mixed in the mixer to be lowered. As a result, the raw material in the mixer can be prevented from becoming highly adhesive, thus allowing the raw material to be easily handled when the raw material is fed from the mixer to the extruder. The second liquid raw material may include one or more selected from the group consisting of water, glycerol, propylene glycol, binder solution, and liquid flavoring.

[0037] The molding step may comprise: a step in which the raw material mixed in the second step is extruded by means of an extruder into a die; and a step in which the raw material is extruded from the die into the form of a sheet.

[0038] The molding step may comprise: a step in which the raw material mixed in the second step is extruded by means of an extruder; and a step in which the raw material extruded from the extruder is formed into a sheet by at least a pair of vertically facing rolling rollers.

[0039] The molding step may comprise: a step in which the raw material mixed in the second step is extruded by means of an extruder; and a step in which the raw material extruded from the extruder is formed into a sheet by being passed between two or more horizontally adjacent rolling rollers.

[0040] A third aspect provides a method for producing a reconstituted pressure-molded tobacco sheet. The production method comprises: a first step in which water and a binder are introduced into and mixed in a mixer to allow the binder to swell; a second step in which a first liquid raw material and a powdered raw material comprising at least tobacco are introduced into the mixer, after the first step, to be mixed with the binder that has been allowed to swell; and a molding step in which the raw materials mixed in the second step are molded into a pressure-molded sheet.

[0041] According to the third aspect, a binder is pre-mixed with water and allowed to swell, and a first liquid raw material and a powdered raw material are mixed while the binding function of the binder is active, thus allowing the viscosity of the raw materials to be increased. As a result, the raw material is easier to handle, and the raw material is also easily extruded by the extruder. The viscosity of the raw material is also increased, thus allowing the strength of the tobacco sheet to be enhanced. As used herein, examples of binders that can be used include 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, gelatinized waxy corn starch, glycerin gum, hydroxypropyl starch, shellac, hydroxypropyl potato starch, phosphate-crosslinked tapioca starch.

[0042] The powdered raw material may include tobacco and an additive.

[0043] In this case, the powdered raw material and the first liquid raw material are mixed, thereby allowing tobacco raw materials in which the viscosity has been increased by the binder to be produced. The additive may comprise, 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 additive is included in the powdered raw material to allow the strength of the tobacco sheet to be increased or to allow flavor to be provided.

[0044] The second step may comprise separately introducing each of the tobacco and the additive into the mixer to be mixed with the binder that has been allowed to swell.

[0045] In this case, the powdered raw materials are each separately mixed with the binder that has been allowed to swell, thus making it possible to further prevent the powdered raw material from becoming lumpy and allowing the raw materials to be more uniformly mixed.

[0046] The first liquid raw material may comprise an aerosol source and an additive.

[0047] In this case, the binder that has been allowed to swell, the powdered raw material, and the first liquid raw material are mixed, thereby allowing tobacco raw materials in which a greater amount of aerosol is generated to be produced. The aerosol source may comprise, for example, one or more selected from the group consisting of glycerol and propylene glycol.

[0048] The additive may also comprise, for example, liquid flavoring. The liquid flavoring is included in the liquid raw material to allow the tobacco sheet to be flavored. The first liquid raw material may further comprise water.

[0049] The second step may comprise separately introducing each of the first liquid raw material and the powdered raw material into the mixer to be mixed with the binder that has been allowed to swell.

[0050] In this case, the first liquid raw material and the powdered raw material are each separately mixed, thus allowing the raw materials to be more uniformly mixed.

[0051] The second step may comprise introducing the first liquid raw material, prior to the powdered raw material, into the mixer to be mixed with the binder that has been allowed to swell.

[0052] In this case, the powdered raw material is introduced and mixed with the binder that has been allowed to swell and the liquid raw material, thus making it possible to prevent the powdered raw material from becoming lumpy and allowing the raw material to be more uniformly mixed.

[0053] The production method may comprise: a step in which the raw material mixed in the second step is fed to an extruder; and a step in which a second liquid raw material is furthermore added to the raw material fed to the extruder.

[0054] The raw material must have moisture suitable for the extrusion process in order for the raw material to be extruded in an extruder. On the other hand, a raw material that is moist enough to be extruded in an extruder will be highly adhesive, and will thus be difficult to handle outside the extruder. Adding a second liquid raw material to the raw material in the extruder will therefore allow the moisture of the raw material to be adjusted in the extruder, and thus allow the amount of the first liquid raw material that is mixed in the mixer to be lowered. As a result, the raw material in the mixer can be prevented from becoming highly adhesive, thus allowing the raw material to be easily handled when the raw material is fed from the mixer to the extruder.

[0055] The second liquid raw material may include water.

[0056] This will allow the amount of the first liquid raw material that is mixed in the mixer to be lowered. As a result, the raw material in the mixer can be prevented from becoming highly adhesive, thus allowing the raw material to be easily handled when the raw material is fed from the mixer to the extruder. The second liquid raw material may include one or more selected from the group consisting of water, glycerol, propylene glycol, binder solution, and liquid flavoring.

[0057] The molding step may comprise: a step in which the raw material mixed in the second step is extruded by means of an extruder into a die; and a step in which the raw material is extruded from the die into the form of a sheet.

[0058] The molding step may comprise: a step in which the raw material mixed in the second step is extruded by means of an extruder; and a step in which the raw material extruded from the extruder is formed into a sheet by at least a pair of vertically facing rolling rollers.

[0059] The molding step may comprise: a step in which the raw material mixed in the second step is extruded by means of an extruder; and a step in which the raw material extruded from the extruder is formed into a sheet by being passed between two or more horizontally adjacent rolling rollers.

[0060] A fourth aspect provides a method for producing a reconstituted pressure-molded tobacco sheet. The production method comprises: a mixing step in which a first liquid raw material and a powdered raw material comprising at least tobacco are introduced into and mixed in a mixer; a step in which the raw material mixed in the mixing step is fed to an extruder; a step in which a second liquid raw material is furthermore added to the raw material fed to the extruder; and a molding step in which the raw material extruded from the extruder is molded into a pressure-molded sheet.

[0061] The raw material must have moisture suitable for the extrusion process in order for the raw material to be extruded in an extruder. On the other hand, a raw material that is moist enough to be extruded in an extruder will be highly adhesive, and will thus be difficult to handle outside the extruder. The fourth aspect thus allows the moisture of the raw material to be adjusted in the extruder, and thus allows the amount of the first liquid raw material that is mixed in the mixer to be lowered. As a result, the raw material in the mixer can be prevented from becoming highly adhesive, thus allowing the raw material to be easily handled when the raw material is fed from the mixer to the extruder.

[0062] The second liquid raw material may include water.

[0063] This will allow the amount of the first liquid raw material that is mixed in the mixer to be lowered. As a result, the raw material in the mixer can be prevented from becoming highly adhesive, thus allowing the raw material to be easily handled when the raw material is fed from the mixer to the extruder. The second liquid raw material may include one or more selected from the group consisting of water, glycerol, propylene glycol, binder solution, and liquid flavoring.

[0064] The mixing step may comprise: a first step in which two or more powdered raw materials are introduced into and mixed in a mixer; and a second step in which a first liquid raw material is introduced, after the first step, into the mixer and mixed with the powdered raw materials.

[0065] In this case, the two or more powdered raw materials are mixed in the first step, thus allowing the powdered raw materials to be thoroughly mixed, before the powdered raw material is mixed with the first liquid raw material.

[0066] The second step may comprise introducing first liquid raw material, which is formed by pre-mixing an aerosol source, water, and an additive, into the mixer.

[0067] In this case, the aerosol source, water, and additive contained in the first liquid raw material are pre-mixed, thus allowing the powdered raw material and the first liquid raw material to be more uniformly mixed.

[0068] The mixing step may comprise: a first step in which a first liquid raw material is introduced into a mixer; and a second step in which a powdered raw material is introduced, after the first step, into the mixer and mixed with the first liquid material.

[0069] In this case, the powdered raw material is mixed with the first liquid raw material, thus making it possible to prevent the powdered raw material from becoming lumpy and allowing the raw materials to be more uniformly mixed.

[0070] The second step may comprise separately introducing and mixing each of tobacco, a binder, and an additive with the first liquid raw material in the mixer.

[0071] In this case, the powdered raw materials are separately mixed with the first liquid raw material, thus making it possible to further prevent the powdered raw material from becoming lumpy and allowing the raw materials to be more uniformly mixed.

[0072] The mixing step may comprise: a first step in which water and a binder are introduced into and mixed in a mixer to allow the binder to swell; and a second step in which a first liquid raw material and a powdered raw material are introduced into the mixer, after the first step, to be mixed with the binder that has been allowed to swell.

[0073] In this case, a binder is pre-mixed with water and allowed to swell, and a first liquid raw material and a powdered raw material are mixed while the binding function of the binder is active, thus allowing the viscosity of the raw materials to be increased. As a result, the raw material is easily extruded by the extruder. The viscosity of the raw material is also increased, thus allowing the strength of the tobacco sheet to be enhanced.

[0074] The second step may comprise separately introducing each of tobacco and an additive into the mixer to be mixed with the binder that has been allowed to swell.

[0075] In this case, the powdered raw materials are each separately mixed with the binder that has been allowed to swell, thus making it possible to further prevent the powdered raw material from becoming lumpy and allowing the raw materials to be more uniformly mixed.

[0076] The second step may comprise separately introducing each of the first liquid raw material and the powdered raw material into the mixer to be mixed with the binder that has been allowed to swell.

[0077] In this case, the first liquid raw material and the powdered raw material are each separately mixed, thus allowing the raw materials to be more uniformly mixed.

[0078] The second step may comprise introducing the first liquid raw material, prior to the powdered raw material, into the mixer to be mixed with the binder that has been allowed to swell.

[0079] In this case, the powdered raw material is introduced and mixed with the binder that has been allowed to swell and the first liquid raw material, thus making it possible to prevent the powdered raw material from becoming lumpy and allowing the raw material to be more uniformly mixed.

[0080] The molding step may comprise: a step in which the raw material is extruded by means of the extruder into a die; and a step in which the raw material is extruded from the die into the form of a sheet.

[0081] The molding step may comprise: a step in which the raw material is extruded by means of the extruder; and a step in which the raw material extruded from the extruder is formed into a sheet by at least a pair of vertically facing rolling rollers.

[0082] The molding step may comprise: a step in which the raw material is extruded by means of the extruder; and a step in which the raw material extruded from the extruder is formed into a sheet by being passed between two or more horizontally adjacent rolling rollers.BRIEF DESCRIPTION OF DRAWINGS

[0083] FIG. 1 is a schematic view of a system for producing a reconstituted pressure-molded tobacco sheet.

[0084] FIG. 2 is a flowchart of a method for producing a reconstituted pressure-molded tobacco sheet using a mixer, an extruder, and a die according to a first embodiment.

[0085] FIG. 3 is a flowchart of a method for producing a reconstituted pressure-molded tobacco sheet using a mixer, an extruder, and a die according to a second embodiment.

[0086] FIG. 4 is a flowchart of a method for producing a reconstituted pressure-molded tobacco sheet using a mixer, an extruder, and a die according to a third embodiment.

[0087] FIG. 5 is a flowchart of a method for producing a reconstituted pressure-molded tobacco sheet using a mixer, an extruder, and a die according to a fourth embodiment.DESCRIPTION OF EMBODIMENTS

[0088] Embodiments of the present invention are described below with reference to the drawings. In the drawings described below, the same or corresponding components are indicated by the same symbols, and will not be described more than once.

[0089] FIG. 1 is a schematic view of a system for producing a reconstituted pressure-molded tobacco sheet. As shown in FIG. 1, the reconstituted pressure-molded tobacco sheet production system 100 comprises: a first grinder 10; a second grinder 20; a classifier 30; a mixer 40; an extruder 50; a die 60; a take-off machine 70; and a dryer 80. In this production system 100, the tobacco is first ground to a predetermined particle size by the first grinder 10. The ground tobacco (tobacco particles) are then ground in a second grinder 20 to a smaller particle size. The tobacco ground by the second grinder 20 is classified by a classifier 30. The tobacco removed by the classifier 30 is again ground in the first and second grinders 10 and 20. The tobacco classified by the classifier 30 is mixed with an additive, for example, in the mixer 40 to produce the raw material for a reconstituted pressure-molded tobacco sheet.

[0090] The raw material is fed to the extruder 50, and is extruded by the extruder 50 into the die 60. The raw material is extruded from the die 60 into the form of a sheet. The raw material in the form of a sheet discharged from the die 60 is taken up by the take-up machine 70 and is dried in a dryer 80 at a later stage. A reconstituted pressure-molded tobacco sheet is thus produced.

[0091] FIG. 2 is a flowchart of a method for producing a reconstituted pressure-molded tobacco sheet using the mixer 40, the extruder 50, and the die 60 according to a first embodiment. In the method for producing a reconstituted pressure-molded tobacco sheet of the first embodiment, two or more powdered raw materials including at least tobacco are first introduced into and mixed in the mixer 40 (first step: step S201). The tobacco may be tobacco leaf of any shape, but is preferably tobacco particles that have been classified in the classifier 30 shown in FIG. 1.

[0092] After the first step, a first liquid raw material is then introduced into the mixer 40 and mixed with the two or more powdered raw materials (second step: step S202). Raw material for a reconstituted pressure-molded tobacco sheet is thus produced. The raw material mixed in the second step is molded into a pressure-molded sheet (molding step). Specifically, the raw material mixed in the second step is fed to the extruder 50 (step S203). The raw material may be highly adhesive, and can therefore be fed by means of a carrier machine such as a belt conveyor to the extruder 50.

[0093] The raw material fed to the extruder 50 is extruded by the extruder 50 into the form of a sheet. According to the production method shown in FIG. 2, two or more powdered raw materials are mixed in the first step S201 before the powdered raw material and the first liquid raw material are mixed, thus allowing two or more powdered raw materials to be thoroughly mixed. Specifically, the raw material fed to the extruder 50 is extruded by the extruder 50 into the die 60 (step S205), and is extruded from the die 60 into the form of a sheet (step S206).

[0094] As shown in FIG. 2, a second liquid raw material may furthermore be added to the raw material fed to the extruder 50 (step S204). The raw material must have moisture suitable for the extrusion process in order for the raw material to be extruded in the extruder 50. On the other hand, raw material that is moist enough to be extruded in the extruder 50 will be highly adhesive, and will thus be difficult to handle outside the extruder 50 (when, for example, conveyed from the mixer 40 to the extruder 50). Adding a second liquid raw material to the raw material in the extruder 50 will therefore allow the moisture of the raw material to be adjusted in the extruder 50, and thus allow the amount of the first liquid raw material that is mixed in the mixer 40 to be lowered. As a result, the raw material in the mixer 40 can be prevented from becoming highly adhesive, thus allowing the raw material to be easily handled when the raw material is fed from the mixer 40 to the extruder 50.

[0095] The second liquid raw material may comprise water. This will allow the amount of the first liquid raw material that is mixed in the mixer 40 to be lowered. As a result, the raw material in the mixer 40 can be prevented from becoming highly adhesive, thus allowing the raw material to be easily handled when the raw material is fed from the mixer 40 to the extruder 50. The second liquid raw material may include one or more selected from the group consisting of water, glycerol, propylene glycol, binder solution, and liquid flavoring.

[0096] In the production method shown in FIG. 2, the two or more powdered raw materials preferably include tobacco, a binder, and an additive. In this case, two or more powdered raw materials and a first liquid raw material are mixed in step S202, thereby allowing tobacco raw materials in which the viscosity has been increased by the binder to be produced. The additive may comprise, 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 additive is included in the powdered raw material to allow the strength of the tobacco sheet to be increased or to allow flavor to be provided.

[0097] In the production method shown in FIG. 2, the first liquid raw material preferably includes an aerosol source, water, and an additive. In this case, the two or more powdered raw materials and the first liquid raw material are mixed in step S202, thereby allowing tobacco raw materials in which a greater amount of aerosol is generated to be produced. The aerosol source may comprise, for example, one or more selected from the group consisting of glycerol and propylene glycol. The additive may also comprise, for example, liquid flavoring. The liquid flavoring is included in the liquid raw material to allow the tobacco sheet to be flavored.

[0098] In the second step (step S202), a first liquid raw material, which is formed by pre-mixing an aerosol source, water, and an additive, may be introduced into the mixer 40. In this case, the aerosol source, water, and additive contained in the first liquid raw material are pre-mixed, thus allowing the powdered raw material and the first liquid raw material to be more uniformly mixed.

[0099] The production method shown in FIG. 2 may comprise, instead of step S205 and step S206, a step in which the raw material mixed in the second step (step S202) is extruded by an extruder 50, and a step in which the raw material extruded from the extruder 50 is formed into a sheet by at least a pair of vertically facing rollers. More specifically, the raw material may be formed in stages into a sheet by three sets of rolling rollers (i.e., six rollers). The production method shown in FIG. 2 may also comprise, instead of step S205 and step S206, a step in which the raw material mixed in the second step (step S202) is extruded by an extruder 50, and a step in which the raw material extruded from the extruder 50 is formed into a sheet by passed through two or more horizontally adjacent rolling rollers. More specifically, the raw material may be formed in stages into a sheet by being passed through each of four horizontally adjacent rolling rollers.

[0100] FIG. 3 is a flowchart of a method for producing a reconstituted pressure-molded tobacco sheet using the mixer 40, the extruder 50, and the die 60 according to a second embodiment. In the method for producing a reconstituted pressure-molded tobacco sheet of the second embodiment, a first liquid raw material is first introduced into a mixer 40 (first step: step S301). After the first step, a powdered starting material comprising at least tobacco is then introduced into the mixer 40 and mixed with the first liquid raw material (second step: step S302). Raw material for a reconstituted pressure-molded tobacco sheet is thus produced. The tobacco may be tobacco leaf of any shape, but is preferably tobacco particles that have been classified in the classifier 30 shown in FIG. 1.

[0101] The raw material mixed in the second step is molded into a pressure-molded sheet (molding step). Specifically, the raw material mixed in the second step is fed to the extruder 50 (step S303). The raw material may be highly adhesive, and can therefore be fed by means of a carrier machine such as a belt conveyor to the extruder 50. The raw material fed to the extruder 50 is extruded by the extruder 50 into the form of a sheet. According to the production method shown in FIG. 3, the powdered raw material is mixed with the first liquid raw material, thus making it possible to prevent the powdered raw material from becoming lumpy and allowing the raw materials to be more uniformly mixed. Specifically, the raw material fed to the extruder 50 is extruded by the extruder 50 into the die 60 (step S305), and is extruded from the die 60 into the form of a sheet (step S306).

[0102] As shown in FIG. 3, a second liquid raw material may furthermore be added to the raw material fed to the extruder 50 (step S304). The raw material must have moisture suitable for the extrusion process in order for the raw material to be extruded in the extruder 50. On the other hand, raw material that is moist enough to be extruded in the extruder 50 will be highly adhesive, and will thus be difficult to handle outside the extruder 50 (when, for example, conveyed from the mixer 40 to the extruder 50). Adding a second liquid raw material to the raw material in the extruder 50 will therefore allow the moisture of the raw material to be adjusted in the extruder 50, and thus allow the amount of the first liquid raw material that is mixed in the mixer 40 to be lowered. As a result, the raw material in the mixer 40 can be prevented from becoming highly adhesive, thus allowing the raw material to be easily handled when the raw material is fed from the mixer 40 to the extruder 50.

[0103] The second liquid raw material may comprise water. This will allow the amount of the first liquid raw material that is mixed in the mixer 40 to be lowered. As a result, the raw material in the mixer 40 can be prevented from becoming highly adhesive, thus allowing the raw material to be easily handled when the raw material is fed from the mixer 40 to the extruder 50. The second liquid raw material may include one or more selected from the group consisting of water, glycerol, propylene glycol, binder solution, and liquid flavoring.

[0104] In the production method shown in FIG. 3, the powdered raw material preferably includes tobacco, a binder, and an additive. In this case, a powdered raw material and a first liquid raw material are mixed in step S302, thereby allowing tobacco raw materials in which the viscosity has been increased by the binder to be produced. The additive may comprise, 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 additive is included in the powdered raw material to allow the strength of the tobacco sheet to be increased or to allow flavor to be provided.

[0105] The second step (step S302) may comprise separately introducing and mixing each of tobacco, a binder, and an additive with the first liquid raw material in the mixer 40. In this case, the powdered raw materials are separately mixed with the first liquid raw material, thus making it possible to further prevent the powdered raw material from becoming lumpy and allowing the raw materials to be more uniformly mixed.

[0106] In the production method shown in FIG. 3, the first liquid raw material preferably includes an aerosol source, water, and an additive. In this case, the powdered raw material and the first liquid raw material are mixed in step S302, thereby allowing tobacco raw materials in which a greater amount of aerosol is generated to be produced. The aerosol source may comprise, for example, one or more selected from the group consisting of glycerol and propylene glycol. The additive may also comprise, for example, liquid flavoring. The liquid flavoring is included in the liquid raw material to allow the tobacco sheet to be flavored.

[0107] The production method shown in FIG. 3 may comprise, instead of step S305 and step S306, a step in which the raw material mixed in the second step (step S302) is extruded by an extruder 50, and a step in which the raw material extruded from the extruder 50 is formed into a sheet by at least a pair of vertically facing rollers. More specifically, the raw material may be formed in stages into a sheet by three sets of rolling rollers (i.e., six rollers). The production method shown in FIG. 3 may also comprise, instead of step S305 and step S306, a step in which the raw material mixed in the second step (step S302) is extruded by an extruder 50, and a step in which the raw material extruded from the extruder 50 is formed into a sheet by passed through two or more horizontally adjacent rolling rollers. More specifically, the raw material may be formed in stages into a sheet by being passed through each of four horizontally adjacent rolling rollers.

[0108] FIG. 4 is a flowchart of a method for producing a reconstituted pressure-molded tobacco sheet using the mixer 40, the extruder 50, and the die 60 according to a third embodiment. In the method for producing a reconstituted pressure-molded tobacco sheet of the third embodiment, water and a binder are first introduced into a mixer 40 and mixed to allow the binder to swell (first step: step S401). After the first step, a first liquid raw material and a powdered starting material comprising at least tobacco are then introduced into the mixer 40 and mixed with the binder that has been allowed to swell (second step: step S402). Raw material for a reconstituted pressure-molded tobacco sheet is thus produced. The tobacco may be tobacco leaf of any shape, but is preferably tobacco particles that have been classified in the classifier 30 shown in FIG. 1.

[0109] The raw material mixed in the second step is molded into a pressure-molded sheet (molding step). Specifically, the raw material mixed in the second step is fed to the extruder 50 (step S403). The raw material may be highly adhesive, and can therefore be fed by means of a carrier machine such as a belt conveyor to the extruder 50. The raw material fed to the extruder 50 is extruded by the extruder 50 into the form of a sheet. According to the production method shown in FIG. 4, a binder is pre-mixed with water and allowed to swell, and a first liquid raw material and a powdered raw material are mixed while the binding function of the binder is active, thus allowing the viscosity of the raw materials to be increased. As a result, the raw material is easier to handle, and the raw material is also easily extruded by the extruder 50. The viscosity of the raw material is also increased, thus allowing the strength of the tobacco sheet to be enhanced. Specifically, the raw material fed to the extruder 50 is extruded by the extruder 50 into the die 60 (step S405), and is extruded from the die 60 into the form of a sheet (step S406).

[0110] As shown in FIG. 4, a second liquid raw material may furthermore be added to the raw material fed to the extruder 50 (step S404). The raw material must have moisture suitable for the extrusion process in order for the raw material to be extruded in the extruder 50. On the other hand, raw material that is moist enough to be extruded in the extruder 50 will be highly adhesive, and will thus be difficult to handle outside the extruder 50 (when, for example, conveyed from the mixer 40 to the extruder 50). Adding a second liquid raw material to the raw material in the extruder 50 will therefore allow the moisture of the raw material to be adjusted in the extruder 50, and thus allow the amount of the first liquid raw material that is mixed in the mixer 40 to be lowered. As a result, the raw material in the mixer 40 can be prevented from becoming highly adhesive, thus allowing the raw material to be easily handled when the raw material is fed from the mixer 40 to the extruder 50.

[0111] The second liquid raw material may comprise water. This will allow the amount of the first liquid raw material that is mixed in the mixer 40 to be lowered. As a result, the raw material in the mixer 40 can be prevented from becoming highly adhesive, thus allowing the raw material to be easily handled when the raw material is fed from the mixer 40 to the extruder 50. The second liquid raw material may include one or more selected from the group consisting of water, glycerol, propylene glycol, binder solution, and liquid flavoring.

[0112] In the production method shown in FIG. 4, the powdered raw material preferably includes tobacco and an additive. In this case, a powdered raw material and a first liquid raw material are mixed in step S402, thereby allowing tobacco raw materials in which the viscosity has been increased by the binder to be produced. The additive may comprise, 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 additive is included in the powdered raw material to allow the strength of the tobacco sheet to be increased or to allow flavor to be provided.

[0113] In the second step (step S402), the tobacco and additive may each be separately introduced into the mixer 40 and mixed with the binder that has been allowed to swell. In this case, the powdered raw materials are each separately mixed with the binder that has been allowed to swell, thus making it possible to further prevent the powdered raw material from becoming lumpy and allowing the raw materials to be more uniformly mixed.

[0114] In the production method shown in FIG. 4, the first liquid raw material preferably includes an aerosol source and an additive. In this case, the binder that has been allowed to swell, the powdered raw material, and the first liquid raw material are mixed in step S402, thereby allowing tobacco raw materials in which a greater amount of aerosol is generated to be produced. The aerosol source may comprise, for example, one or more selected from the group consisting of glycerol and propylene glycol. The additive may also comprise, for example, liquid flavoring. The liquid flavoring is included in the liquid raw material to allow the tobacco sheet to be flavored.

[0115] In the second step (step S402), the first liquid raw material and powdered raw material may each be separately introduced into the mixer 40 and mixed with the binder that has been allowed to swell. The first liquid raw material and the powdered raw material are each thereby separately mixed, thus allowing the raw materials to be more uniformly mixed. Furthermore, in this case, the first liquid raw material is preferably introduced, prior to the powdered raw material, into the mixer 40 to be mixed with the binder that has been allowed to swell in the second step (step S402). The powdered raw material is thereby introduced and mixed with the binder that has been allowed to swell and the liquid raw material, thus making it possible to prevent the powdered raw material from becoming lumpy and allowing the raw material to be more uniformly mixed.

[0116] The production method shown in FIG. 4 may comprise, instead of step S405 and step S406, a step in which the raw material mixed in the second step (step S402) is extruded by an extruder 50, and a step in which the raw material extruded from the extruder 50 is formed into a sheet by at least a pair of vertically facing rollers. More specifically, the raw material may be formed in stages into a sheet by three sets of rolling rollers (i.e., six rollers). The production method shown in FIG. 4 may also comprise, instead of step S405 and step S406, a step in which the raw material mixed in the second step (step S402) is extruded by an extruder 50, and a step in which the raw material extruded from the extruder 50 is formed into a sheet by being passed through two or more horizontally adjacent rolling rollers. More specifically, the raw material may be formed in stages into a sheet by being passed through each of four horizontally adjacent rolling rollers.

[0117] FIG. 5 is a flowchart of a method for producing a reconstituted pressure-molded tobacco sheet using the mixer 40, extruder 50, and die 60 according to a fourth embodiment. In the method for producing a reconstituted pressure-molded tobacco sheet of the fourth embodiment, powdered raw material including at least tobacco and a first liquid raw material are first introduced into and mixed in the mixer 40 (mixing step: step S501). The tobacco may be tobacco leaf of any shape, but is preferably tobacco particles that have been classified in the classifier 30 shown in FIG. 1. The raw material mixed in the mixing step is then fed to the extruder 50 (step S502). The raw material may be highly adhesive, and can therefore be fed by means of a carrier machine such as a belt conveyor to the extruder 50.

[0118] In the fourth embodiment here, a second liquid raw material is furthermore added to the raw material fed to the extruder 50 (step S503). The raw material extruded from the extruder 50 is molded into a pressure-molded sheet (molding step). Specifically, the raw material fed to the extruder 50 is extruded in the form of a sheet. More specifically, the raw material fed to the extruder 50 is extruded by the extruder 50 into the die 60 (step S504), and is extruded from the die 60 into the form of a sheet (step S505).

[0119] As described above, the raw material must have moisture suitable for the extrusion process in order for the raw material to be extruded in the extruder 50. On the other hand, raw material that is moist enough to be extruded in the extruder 50 will be highly adhesive, and will thus be difficult to handle outside the extruder 50 (when, for example, conveyed from the mixer 40 to the extruder 50). The fourth embodiment thus allows the moisture of the raw material to be adjusted in the extruder, and thus allow the amount of the first liquid raw material that is mixed in the mixer to be lowered. As a result, the raw material in the mixer 40 can be prevented from becoming highly adhesive, thus allowing the raw material to be easily handled when the raw material is fed from the mixer 40 to the extruder 50.

[0120] The second liquid raw material in step S503 may comprise water. This will allow the amount of the first liquid raw material that is mixed in the mixer 40 to be lowered. As a result, the raw material in the mixer 40 can be prevented from becoming highly adhesive, thus allowing the raw material to be easily handled when the raw material is fed from the mixer 40 to the extruder 50. The second liquid raw material may include one or more selected from the group consisting of water, glycerol, propylene glycol, binder solution, and liquid flavoring.

[0121] The mixing step (step S501) may comprise: a first step in which two or more powdered raw materials are introduced into and mixed in the mixer 40; and a second step in which a first liquid raw material is introduced, after the first step, into the mixer 40 and mixed with the powdered raw materials. In this case, the two or more powdered raw materials are mixed in the first step, thus allowing the powdered raw materials to be thoroughly mixed, before the powdered raw material is mixed with the first liquid raw material. In the second step, a first liquid raw material, which is formed by pre-mixing an aerosol source, water, and an additive, may be introduced into the mixer 40. In this case, the aerosol source, water, and additive contained in the first liquid raw material are pre-mixed, thus allowing the powdered raw material and the first liquid raw material to be more uniformly mixed.

[0122] Alternatively, the mixing step (step S501) may comprise: a first step in which a first liquid raw material is introduced into the mixer 40; and a second step in which a powdered raw material is introduced, after the first step, into the mixer 40 and mixed with the first liquid material. In this case, the powdered raw material is mixed with the first liquid raw material, thus making it possible to prevent the powdered raw material from becoming lumpy and allowing the raw materials to be more uniformly mixed. In the second step, tobacco, a binder, and an additive may each be separately introduced and mixed the first liquid raw material in the mixer 40. In this case, the powdered raw materials are separately mixed with the first liquid raw material, thus making it possible to further prevent the powdered raw material from becoming lumpy and allowing the raw materials to be more uniformly mixed.

[0123] Alternatively, the mixing step (step S501) may comprise: a first step in which water and a binder are introduced into and mixed in the mixer 40 to allow the binder to swell; and a second step in which a first liquid raw material and a powdered raw material are introduced into the mixer 40, after the first step, to be mixed with the binder that has been allowed to swell. In this case, a binder is pre-mixed with water and allowed to swell, and a first liquid raw material and a powdered raw material are mixed while the binding function of the binder is active, thus allowing the viscosity of the raw materials to be increased. As a result, the raw material is easily extruded by the extruder 50. The viscosity of the raw material is also increased, thus allowing the strength of the tobacco sheet to be enhanced. In the second step, the tobacco and additive may each be separately introduced into the mixer 40 and mixed with the binder that has been allowed to swell. In this case, the powdered raw materials are each separately mixed with the binder that has been allowed to swell, thus making it possible to further prevent the powdered raw material from becoming lumpy and allowing the raw materials to be more uniformly mixed.

[0124] In the second step, the first liquid raw material and the powdered raw material may also each be separately introduced into the mixer 40 to be mixed with the binder that has been allowed to swell. The first liquid raw material and the powdered raw material are each thereby separately mixed, thus allowing the raw materials to be more uniformly mixed. In this case, the second step may comprise introducing the first liquid raw material, prior to the powdered raw material, into the mixer 40 to be mixed with the binder that has been allowed to swell. The powdered raw material is thereby introduced and mixed with the binder that has been allowed to swell and the first liquid raw material, thus making it possible to prevent the powdered raw material from becoming lumpy and allowing the raw material to be more uniformly mixed.

[0125] The production method shown in FIG. 5 may comprise, instead of step S504 and step S505, a step in which the raw material mixed in the second step (step S502) is extruded by an extruder 50, and a step in which the raw material extruded from the extruder 50 is formed into a sheet by at least a pair of vertically facing rollers. More specifically, the raw material may be formed in stages into a sheet by three sets of rolling rollers (i.e., six rollers). The production method shown in FIG. 5 may also comprise, instead of step S504 and step S505, a step in which the raw material mixed in the second step (step S502) is extruded by an extruder 50, and a step in which the raw material extruded from the extruder 50 is formed into a sheet by passed through two or more horizontally adjacent rolling rollers. More specifically, the raw material may be formed in stages into a sheet by being passed through each of four horizontally adjacent rolling rollers.

[0126] Embodiments of the present invention were described above, but the present invention is not limited to those embodiments, and various modifications are possible within the scope of the technical concept disclosed in the claims, specification and drawings.

[0127] Moreover, any shape or material not directly stated in the specification or drawings is also within the scope of the technical concept of the invention of this application, provided that it exhibits the action and effect of the invention of this application.REFERENCE SIGNS LIST

[0128] 40: Mixer

[0129] 50: Extruder

Examples

Embodiment Construction

[0088]Embodiments of the present invention are described below with reference to the drawings. In the drawings described below, the same or corresponding components are indicated by the same symbols, and will not be described more than once.

[0089]FIG. 1 is a schematic view of a system for producing a reconstituted pressure-molded tobacco sheet. As shown in FIG. 1, the reconstituted pressure-molded tobacco sheet production system 100 comprises: a first grinder 10; a second grinder 20; a classifier 30; a mixer 40; an extruder 50; a die 60; a take-off machine 70; and a dryer 80. In this production system 100, the tobacco is first ground to a predetermined particle size by the first grinder 10. The ground tobacco (tobacco particles) are then ground in a second grinder 20 to a smaller particle size. The tobacco ground by the second grinder 20 is classified by a classifier 30. The tobacco removed by the classifier 30 is again ground in the first and second grinders 10 and 20. The tobacco ...

TECHNICAL FIELD

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

[0002] Rolling methods, casting (slurry) methods, and sheet-forming methods are conventionally known methods for producing reconstituted tobacco sheets. These manufacturing methods are selected depending on the amount of moisture contained in the reconstituted tobacco raw material. The devices for producing reconstituted tobacco sheets that are employed in these methods of production are also different from each other.

[0003] Rolling methods are known to be particularly suitable for reconstituted tobacco raw materials that contain up to 50% by volume of moisture. In rolling methods, kneaded reconstituted tobacco raw materials are rolled and formed by means of rotating rollers, the thickness is adjusted, and the material is then dried in a separately provided dryer.

[0004] Casting (slurry) methods are known to be particularly suitable for reconstituted tobacco raw materials that contain 50% by volume or more of moisture. In casting (slurry) methods, a reconstituted tobacco raw material fluid is continuously spread onto a rotating drum or belt conveyor, is leveled to a desired thickness with a member called a blade, is then released from the rotating drum or the belt conveyor, and is dried in a separately provided dryer.

[0005] Sheet-forming methods are known to be particularly suitable for reconstituted tobacco raw materials that contain 80% by volume or more of moisture. In sheet-forming methods, a reconstituted tobacco raw material fluid is continuously spread onto a liquid-permeable belt conveyor, moisture is removed and the desired thickness is achieved by means of squeeze rolls, and the material is then dried in a separately provided dryer.

[0006] In contrast to these production methods, which are selected depending on the moisture content, there are a known device and method for producing a reconstituted tobacco sheet that allow a reconstituted tobacco sheet of uniform thickness to be obtained via a simple production process, regardless of the amount of moisture contained in the reconstituted tobacco raw material (see PTL 1).CITATION LISTPatent Literature

[0007] PTL 1: International Publication No. 2022 / 019027SUMMARY OF INVENTIONTechnical Problem

[0008] In cases where reconstituted tobacco sheets are pressure-molded, such as in the method disclosed in PTL 1 or in rolling methods, no consideration has been given to methods for producing reconstituted pressure-molded tobacco raw materials.

[0009] An object of the present invention is to provide a novel method for producing a reconstituted pressure-molded tobacco sheet.Solution to Problem

[0010] A first aspect provides a method for producing a reconstituted pressure-molded tobacco sheet. The production method comprises: a first step in which two or more powdered raw materials comprising at least tobacco are introduced into and mixed in a mixer; a second step in which a first liquid raw material is introduced, after the first step, into the mixer and mixed with the two or more powdered raw materials; and a molding step in which the raw materials mixed in the second step are molded into a pressure-molded sheet.

[0011] According to the first aspect, the two or more powdered raw materials are mixed in the first step before the powdered raw material and the first liquid raw material are mixed, thus allowing the two or more powdered raw materials to be thoroughly mixed.

[0012] The two or more powdered raw materials may comprise tobacco, a binder, and an additive.

[0013] In this case, the powdered raw material and the first liquid raw material are mixed, thereby allowing tobacco raw materials in which the viscosity has been increased by the binder to be produced. The additive may comprise, 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 additive is included in the powdered raw material to allow the strength of the tobacco sheet to be increased or to allow flavor to be provided.

[0014] The first liquid raw material may comprise an aerosol source, water, and an additive.

[0015] In this case, the powdered raw material and the first liquid raw material are mixed, thereby allowing tobacco raw materials in which a greater amount of aerosol is generated to be produced. The aerosol source may comprise, for example, one or more selected from the group consisting of glycerol and propylene glycol. The additive may also comprise, for example, liquid flavoring. The liquid flavoring is included in the liquid raw material to allow the tobacco sheet to be flavored.

[0016] The second step may comprise introducing 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 additive contained in the first liquid raw material are pre-mixed, thus allowing the powdered raw material and the first liquid raw material to be more uniformly mixed.

[0018] The production method may comprise: a step in which the raw material mixed in the second step is fed to an extruder; and a step in which a second liquid raw material is furthermore added to the raw material fed to the extruder.

[0019] The raw material must have moisture suitable for the extrusion process in order for the raw material to be extruded in an extruder. On the other hand, a raw material that is moist enough to be extruded in an extruder will be highly adhesive, and will thus be difficult to handle outside the extruder. Adding a second liquid raw material to the raw material in the extruder will therefore allow the moisture of the raw material to be adjusted in the extruder, and thus allow the amount of the first liquid raw material that is mixed in the mixer to be lowered. As a result, the raw material in the mixer can be prevented from becoming highly adhesive, thus allowing the raw material to be easily handled when the raw material is fed from the mixer to the extruder.

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

[0021] This will allow the amount of the first liquid raw material that is mixed in the mixer to be lowered. As a result, the raw material in the mixer can be prevented from becoming highly adhesive, thus allowing the raw material to be easily handled when the raw material is fed from the mixer to the extruder. The second liquid raw material may include one or more selected from the group consisting of water, glycerol, propylene glycol, binder solution, and liquid flavoring.

[0022] The molding step may comprise: a step in which the raw material mixed in the second step is extruded by means of an extruder into a die; and a step in which the raw material is extruded from the die into the form of a sheet.

[0023] The molding step may comprise: a step in which the raw material mixed in the second step is extruded by means of an extruder; and a step in which the raw material extruded from the extruder is formed into a sheet by at least a pair of vertically facing rolling rollers.

[0024] The molding step may comprise: a step in which the raw material mixed in the second step is extruded by means of an extruder; and a step in which the raw material extruded from the extruder is formed into a sheet by being passed between two or more horizontally adjacent rolling rollers.

[0025] A second aspect provides a method for producing a reconstituted pressure-molded tobacco sheet. The production method comprises: a first step in which a first liquid raw material is introduced into a mixer; a second step in which a powdered raw material comprising at least tobacco is introduced, after the first step, into the mixer and mixed with the first liquid raw material; and a molding step in which the raw materials mixed in the second step are molded into a pressure-molded sheet.

[0026] According to the second aspect, the powdered raw material is mixed with the first liquid raw material, thus making it possible to prevent the powdered raw material from becoming lumpy and allowing the raw materials to be more uniformly mixed.

[0027] The powdered raw material may include tobacco, a binder, and an additive.

[0028] In this case, the powdered raw material and the first liquid raw material are mixed, thereby allowing tobacco raw materials in which the viscosity has been increased by the binder to be produced. The additive may comprise, 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 additive is included in the powdered raw material to allow the strength of the tobacco sheet to be increased or to allow flavor to be provided.

[0029] The second step may comprise separately introducing and mixing each of the tobacco, the binder, and the additive with the first liquid raw material in the mixer.

[0030] In this case, the powdered raw materials are separately mixed with the first liquid raw material, thus making it possible to further prevent the powdered raw material from becoming lumpy and allowing the raw materials to be more uniformly mixed.

[0031] The first liquid raw material may comprise an aerosol source, water, and an additive.

[0032] In this case, the powdered raw material and the first liquid raw material are mixed, thereby allowing tobacco raw materials in which a greater amount of aerosol is generated to be produced. The aerosol source may comprise, for example, one or more selected from the group consisting of glycerol and propylene glycol. The additive may also comprise, for example, liquid flavoring. The liquid flavoring is included in the liquid raw material to allow the tobacco sheet to be flavored.

[0033] The production method may comprise: a step in which the raw material mixed in the second step is fed to an extruder; and a step in which a second liquid raw material is furthermore added to the raw material fed to the extruder.

[0034] The raw material must have moisture suitable for the extrusion process in order for the raw material to be extruded in an extruder. On the other hand, a raw material that is moist enough to be extruded in an extruder will be highly adhesive, and will thus be difficult to handle outside the extruder. Adding a second liquid raw material to the raw material in the extruder will therefore allow the moisture of the raw material to be adjusted in the extruder, and thus allow the amount of the first liquid raw material that is mixed in the mixer to be lowered. As a result, the raw material in the mixer can be prevented from becoming highly adhesive, thus allowing the raw material to be easily handled when the raw material is fed from the mixer to the extruder.

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

[0036] This will allow the amount of the first liquid raw material that is mixed in the mixer to be lowered. As a result, the raw material in the mixer can be prevented from becoming highly adhesive, thus allowing the raw material to be easily handled when the raw material is fed from the mixer to the extruder. The second liquid raw material may include one or more selected from the group consisting of water, glycerol, propylene glycol, binder solution, and liquid flavoring.

[0037] The molding step may comprise: a step in which the raw material mixed in the second step is extruded by means of an extruder into a die; and a step in which the raw material is extruded from the die into the form of a sheet.

[0038] The molding step may comprise: a step in which the raw material mixed in the second step is extruded by means of an extruder; and a step in which the raw material extruded from the extruder is formed into a sheet by at least a pair of vertically facing rolling rollers.

[0039] The molding step may comprise: a step in which the raw material mixed in the second step is extruded by means of an extruder; and a step in which the raw material extruded from the extruder is formed into a sheet by being passed between two or more horizontally adjacent rolling rollers.

[0040] A third aspect provides a method for producing a reconstituted pressure-molded tobacco sheet. The production method comprises: a first step in which water and a binder are introduced into and mixed in a mixer to allow the binder to swell; a second step in which a first liquid raw material and a powdered raw material comprising at least tobacco are introduced into the mixer, after the first step, to be mixed with the binder that has been allowed to swell; and a molding step in which the raw materials mixed in the second step are molded into a pressure-molded sheet.

[0041] According to the third aspect, a binder is pre-mixed with water and allowed to swell, and a first liquid raw material and a powdered raw material are mixed while the binding function of the binder is active, thus allowing the viscosity of the raw materials to be increased. As a result, the raw material is easier to handle, and the raw material is also easily extruded by the extruder. The viscosity of the raw material is also increased, thus allowing the strength of the tobacco sheet to be enhanced. As used herein, examples of binders that can be used include 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, gelatinized waxy corn starch, glycerin gum, hydroxypropyl starch, shellac, hydroxypropyl potato starch, phosphate-crosslinked tapioca starch.

[0042] The powdered raw material may include tobacco and an additive.

[0043] In this case, the powdered raw material and the first liquid raw material are mixed, thereby allowing tobacco raw materials in which the viscosity has been increased by the binder to be produced. The additive may comprise, 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 additive is included in the powdered raw material to allow the strength of the tobacco sheet to be increased or to allow flavor to be provided.

[0044] The second step may comprise separately introducing each of the tobacco and the additive into the mixer to be mixed with the binder that has been allowed to swell.

[0045] In this case, the powdered raw materials are each separately mixed with the binder that has been allowed to swell, thus making it possible to further prevent the powdered raw material from becoming lumpy and allowing the raw materials to be more uniformly mixed.

[0046] The first liquid raw material may comprise an aerosol source and an additive.

[0047] In this case, the binder that has been allowed to swell, the powdered raw material, and the first liquid raw material are mixed, thereby allowing tobacco raw materials in which a greater amount of aerosol is generated to be produced. The aerosol source may comprise, for example, one or more selected from the group consisting of glycerol and propylene glycol.

[0048] The additive may also comprise, for example, liquid flavoring. The liquid flavoring is included in the liquid raw material to allow the tobacco sheet to be flavored. The first liquid raw material may further comprise water.

[0049] The second step may comprise separately introducing each of the first liquid raw material and the powdered raw material into the mixer to be mixed with the binder that has been allowed to swell.

[0050] In this case, the first liquid raw material and the powdered raw material are each separately mixed, thus allowing the raw materials to be more uniformly mixed.

[0051] The second step may comprise introducing the first liquid raw material, prior to the powdered raw material, into the mixer to be mixed with the binder that has been allowed to swell.

[0052] In this case, the powdered raw material is introduced and mixed with the binder that has been allowed to swell and the liquid raw material, thus making it possible to prevent the powdered raw material from becoming lumpy and allowing the raw material to be more uniformly mixed.

[0053] The production method may comprise: a step in which the raw material mixed in the second step is fed to an extruder; and a step in which a second liquid raw material is furthermore added to the raw material fed to the extruder.

[0054] The raw material must have moisture suitable for the extrusion process in order for the raw material to be extruded in an extruder. On the other hand, a raw material that is moist enough to be extruded in an extruder will be highly adhesive, and will thus be difficult to handle outside the extruder. Adding a second liquid raw material to the raw material in the extruder will therefore allow the moisture of the raw material to be adjusted in the extruder, and thus allow the amount of the first liquid raw material that is mixed in the mixer to be lowered. As a result, the raw material in the mixer can be prevented from becoming highly adhesive, thus allowing the raw material to be easily handled when the raw material is fed from the mixer to the extruder.

[0055] The second liquid raw material may include water.

[0056] This will allow the amount of the first liquid raw material that is mixed in the mixer to be lowered. As a result, the raw material in the mixer can be prevented from becoming highly adhesive, thus allowing the raw material to be easily handled when the raw material is fed from the mixer to the extruder. The second liquid raw material may include one or more selected from the group consisting of water, glycerol, propylene glycol, binder solution, and liquid flavoring.

[0057] The molding step may comprise: a step in which the raw material mixed in the second step is extruded by means of an extruder into a die; and a step in which the raw material is extruded from the die into the form of a sheet.

[0058] The molding step may comprise: a step in which the raw material mixed in the second step is extruded by means of an extruder; and a step in which the raw material extruded from the extruder is formed into a sheet by at least a pair of vertically facing rolling rollers.

[0059] The molding step may comprise: a step in which the raw material mixed in the second step is extruded by means of an extruder; and a step in which the raw material extruded from the extruder is formed into a sheet by being passed between two or more horizontally adjacent rolling rollers.

[0060] A fourth aspect provides a method for producing a reconstituted pressure-molded tobacco sheet. The production method comprises: a mixing step in which a first liquid raw material and a powdered raw material comprising at least tobacco are introduced into and mixed in a mixer; a step in which the raw material mixed in the mixing step is fed to an extruder; a step in which a second liquid raw material is furthermore added to the raw material fed to the extruder; and a molding step in which the raw material extruded from the extruder is molded into a pressure-molded sheet.

[0061] The raw material must have moisture suitable for the extrusion process in order for the raw material to be extruded in an extruder. On the other hand, a raw material that is moist enough to be extruded in an extruder will be highly adhesive, and will thus be difficult to handle outside the extruder. The fourth aspect thus allows the moisture of the raw material to be adjusted in the extruder, and thus allows the amount of the first liquid raw material that is mixed in the mixer to be lowered. As a result, the raw material in the mixer can be prevented from becoming highly adhesive, thus allowing the raw material to be easily handled when the raw material is fed from the mixer to the extruder.

[0062] The second liquid raw material may include water.

[0063] This will allow the amount of the first liquid raw material that is mixed in the mixer to be lowered. As a result, the raw material in the mixer can be prevented from becoming highly adhesive, thus allowing the raw material to be easily handled when the raw material is fed from the mixer to the extruder. The second liquid raw material may include one or more selected from the group consisting of water, glycerol, propylene glycol, binder solution, and liquid flavoring.

[0064] The mixing step may comprise: a first step in which two or more powdered raw materials are introduced into and mixed in a mixer; and a second step in which a first liquid raw material is introduced, after the first step, into the mixer and mixed with the powdered raw materials.

[0065] In this case, the two or more powdered raw materials are mixed in the first step, thus allowing the powdered raw materials to be thoroughly mixed, before the powdered raw material is mixed with the first liquid raw material.

[0066] The second step may comprise introducing first liquid raw material, which is formed by pre-mixing an aerosol source, water, and an additive, into the mixer.

[0067] In this case, the aerosol source, water, and additive contained in the first liquid raw material are pre-mixed, thus allowing the powdered raw material and the first liquid raw material to be more uniformly mixed.

[0068] The mixing step may comprise: a first step in which a first liquid raw material is introduced into a mixer; and a second step in which a powdered raw material is introduced, after the first step, into the mixer and mixed with the first liquid material.

[0069] In this case, the powdered raw material is mixed with the first liquid raw material, thus making it possible to prevent the powdered raw material from becoming lumpy and allowing the raw materials to be more uniformly mixed.

[0070] The second step may comprise separately introducing and mixing each of tobacco, a binder, and an additive with the first liquid raw material in the mixer.

[0071] In this case, the powdered raw materials are separately mixed with the first liquid raw material, thus making it possible to further prevent the powdered raw material from becoming lumpy and allowing the raw materials to be more uniformly mixed.

[0072] The mixing step may comprise: a first step in which water and a binder are introduced into and mixed in a mixer to allow the binder to swell; and a second step in which a first liquid raw material and a powdered raw material are introduced into the mixer, after the first step, to be mixed with the binder that has been allowed to swell.

[0073] In this case, a binder is pre-mixed with water and allowed to swell, and a first liquid raw material and a powdered raw material are mixed while the binding function of the binder is active, thus allowing the viscosity of the raw materials to be increased. As a result, the raw material is easily extruded by the extruder. The viscosity of the raw material is also increased, thus allowing the strength of the tobacco sheet to be enhanced.

[0074] The second step may comprise separately introducing each of tobacco and an additive into the mixer to be mixed with the binder that has been allowed to swell.

[0075] In this case, the powdered raw materials are each separately mixed with the binder that has been allowed to swell, thus making it possible to further prevent the powdered raw material from becoming lumpy and allowing the raw materials to be more uniformly mixed.

[0076] The second step may comprise separately introducing each of the first liquid raw material and the powdered raw material into the mixer to be mixed with the binder that has been allowed to swell.

[0077] In this case, the first liquid raw material and the powdered raw material are each separately mixed, thus allowing the raw materials to be more uniformly mixed.

[0078] The second step may comprise introducing the first liquid raw material, prior to the powdered raw material, into the mixer to be mixed with the binder that has been allowed to swell.

[0079] In this case, the powdered raw material is introduced and mixed with the binder that has been allowed to swell and the first liquid raw material, thus making it possible to prevent the powdered raw material from becoming lumpy and allowing the raw material to be more uniformly mixed.

[0080] The molding step may comprise: a step in which the raw material is extruded by means of the extruder into a die; and a step in which the raw material is extruded from the die into the form of a sheet.

[0081] The molding step may comprise: a step in which the raw material is extruded by means of the extruder; and a step in which the raw material extruded from the extruder is formed into a sheet by at least a pair of vertically facing rolling rollers.

[0082] The molding step may comprise: a step in which the raw material is extruded by means of the extruder; and a step in which the raw material extruded from the extruder is formed into a sheet by being passed between two or more horizontally adjacent rolling rollers.BRIEF DESCRIPTION OF DRAWINGS

[0083] FIG. 1 is a schematic view of a system for producing a reconstituted pressure-molded tobacco sheet.

[0084] FIG. 2 is a flowchart of a method for producing a reconstituted pressure-molded tobacco sheet using a mixer, an extruder, and a die according to a first embodiment.

[0085] FIG. 3 is a flowchart of a method for producing a reconstituted pressure-molded tobacco sheet using a mixer, an extruder, and a die according to a second embodiment.

[0086] FIG. 4 is a flowchart of a method for producing a reconstituted pressure-molded tobacco sheet using a mixer, an extruder, and a die according to a third embodiment.

[0087] FIG. 5 is a flowchart of a method for producing a reconstituted pressure-molded tobacco sheet using a mixer, an extruder, and a die according to a fourth embodiment.DESCRIPTION OF EMBODIMENTS

[0088] Embodiments of the present invention are described below with reference to the drawings. In the drawings described below, the same or corresponding components are indicated by the same symbols, and will not be described more than once.

[0089] FIG. 1 is a schematic view of a system for producing a reconstituted pressure-molded tobacco sheet. As shown in FIG. 1, the reconstituted pressure-molded tobacco sheet production system 100 comprises: a first grinder 10; a second grinder 20; a classifier 30; a mixer 40; an extruder 50; a die 60; a take-off machine 70; and a dryer 80. In this production system 100, the tobacco is first ground to a predetermined particle size by the first grinder 10. The ground tobacco (tobacco particles) are then ground in a second grinder 20 to a smaller particle size. The tobacco ground by the second grinder 20 is classified by a classifier 30. The tobacco removed by the classifier 30 is again ground in the first and second grinders 10 and 20. The tobacco classified by the classifier 30 is mixed with an additive, for example, in the mixer 40 to produce the raw material for a reconstituted pressure-molded tobacco sheet.

[0090] The raw material is fed to the extruder 50, and is extruded by the extruder 50 into the die 60. The raw material is extruded from the die 60 into the form of a sheet. The raw material in the form of a sheet discharged from the die 60 is taken up by the take-up machine 70 and is dried in a dryer 80 at a later stage. A reconstituted pressure-molded tobacco sheet is thus produced.

[0091] FIG. 2 is a flowchart of a method for producing a reconstituted pressure-molded tobacco sheet using the mixer 40, the extruder 50, and the die 60 according to a first embodiment. In the method for producing a reconstituted pressure-molded tobacco sheet of the first embodiment, two or more powdered raw materials including at least tobacco are first introduced into and mixed in the mixer 40 (first step: step S201). The tobacco may be tobacco leaf of any shape, but is preferably tobacco particles that have been classified in the classifier 30 shown in FIG. 1.

[0092] After the first step, a first liquid raw material is then introduced into the mixer 40 and mixed with the two or more powdered raw materials (second step: step S202). Raw material for a reconstituted pressure-molded tobacco sheet is thus produced. The raw material mixed in the second step is molded into a pressure-molded sheet (molding step). Specifically, the raw material mixed in the second step is fed to the extruder 50 (step S203). The raw material may be highly adhesive, and can therefore be fed by means of a carrier machine such as a belt conveyor to the extruder 50.

[0093] The raw material fed to the extruder 50 is extruded by the extruder 50 into the form of a sheet. According to the production method shown in FIG. 2, two or more powdered raw materials are mixed in the first step S201 before the powdered raw material and the first liquid raw material are mixed, thus allowing two or more powdered raw materials to be thoroughly mixed. Specifically, the raw material fed to the extruder 50 is extruded by the extruder 50 into the die 60 (step S205), and is extruded from the die 60 into the form of a sheet (step S206).

[0094] As shown in FIG. 2, a second liquid raw material may furthermore be added to the raw material fed to the extruder 50 (step S204). The raw material must have moisture suitable for the extrusion process in order for the raw material to be extruded in the extruder 50. On the other hand, raw material that is moist enough to be extruded in the extruder 50 will be highly adhesive, and will thus be difficult to handle outside the extruder 50 (when, for example, conveyed from the mixer 40 to the extruder 50). Adding a second liquid raw material to the raw material in the extruder 50 will therefore allow the moisture of the raw material to be adjusted in the extruder 50, and thus allow the amount of the first liquid raw material that is mixed in the mixer 40 to be lowered. As a result, the raw material in the mixer 40 can be prevented from becoming highly adhesive, thus allowing the raw material to be easily handled when the raw material is fed from the mixer 40 to the extruder 50.

[0095] The second liquid raw material may comprise water. This will allow the amount of the first liquid raw material that is mixed in the mixer 40 to be lowered. As a result, the raw material in the mixer 40 can be prevented from becoming highly adhesive, thus allowing the raw material to be easily handled when the raw material is fed from the mixer 40 to the extruder 50. The second liquid raw material may include one or more selected from the group consisting of water, glycerol, propylene glycol, binder solution, and liquid flavoring.

[0096] In the production method shown in FIG. 2, the two or more powdered raw materials preferably include tobacco, a binder, and an additive. In this case, two or more powdered raw materials and a first liquid raw material are mixed in step S202, thereby allowing tobacco raw materials in which the viscosity has been increased by the binder to be produced. The additive may comprise, 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 additive is included in the powdered raw material to allow the strength of the tobacco sheet to be increased or to allow flavor to be provided.

[0097] In the production method shown in FIG. 2, the first liquid raw material preferably includes an aerosol source, water, and an additive. In this case, the two or more powdered raw materials and the first liquid raw material are mixed in step S202, thereby allowing tobacco raw materials in which a greater amount of aerosol is generated to be produced. The aerosol source may comprise, for example, one or more selected from the group consisting of glycerol and propylene glycol. The additive may also comprise, for example, liquid flavoring. The liquid flavoring is included in the liquid raw material to allow the tobacco sheet to be flavored.

[0098] In the second step (step S202), a first liquid raw material, which is formed by pre-mixing an aerosol source, water, and an additive, may be introduced into the mixer 40. In this case, the aerosol source, water, and additive contained in the first liquid raw material are pre-mixed, thus allowing the powdered raw material and the first liquid raw material to be more uniformly mixed.

[0099] The production method shown in FIG. 2 may comprise, instead of step S205 and step S206, a step in which the raw material mixed in the second step (step S202) is extruded by an extruder 50, and a step in which the raw material extruded from the extruder 50 is formed into a sheet by at least a pair of vertically facing rollers. More specifically, the raw material may be formed in stages into a sheet by three sets of rolling rollers (i.e., six rollers). The production method shown in FIG. 2 may also comprise, instead of step S205 and step S206, a step in which the raw material mixed in the second step (step S202) is extruded by an extruder 50, and a step in which the raw material extruded from the extruder 50 is formed into a sheet by passed through two or more horizontally adjacent rolling rollers. More specifically, the raw material may be formed in stages into a sheet by being passed through each of four horizontally adjacent rolling rollers.

[0100] FIG. 3 is a flowchart of a method for producing a reconstituted pressure-molded tobacco sheet using the mixer 40, the extruder 50, and the die 60 according to a second embodiment. In the method for producing a reconstituted pressure-molded tobacco sheet of the second embodiment, a first liquid raw material is first introduced into a mixer 40 (first step: step S301). After the first step, a powdered starting material comprising at least tobacco is then introduced into the mixer 40 and mixed with the first liquid raw material (second step: step S302). Raw material for a reconstituted pressure-molded tobacco sheet is thus produced. The tobacco may be tobacco leaf of any shape, but is preferably tobacco particles that have been classified in the classifier 30 shown in FIG. 1.

[0101] The raw material mixed in the second step is molded into a pressure-molded sheet (molding step). Specifically, the raw material mixed in the second step is fed to the extruder 50 (step S303). The raw material may be highly adhesive, and can therefore be fed by means of a carrier machine such as a belt conveyor to the extruder 50. The raw material fed to the extruder 50 is extruded by the extruder 50 into the form of a sheet. According to the production method shown in FIG. 3, the powdered raw material is mixed with the first liquid raw material, thus making it possible to prevent the powdered raw material from becoming lumpy and allowing the raw materials to be more uniformly mixed. Specifically, the raw material fed to the extruder 50 is extruded by the extruder 50 into the die 60 (step S305), and is extruded from the die 60 into the form of a sheet (step S306).

[0102] As shown in FIG. 3, a second liquid raw material may furthermore be added to the raw material fed to the extruder 50 (step S304). The raw material must have moisture suitable for the extrusion process in order for the raw material to be extruded in the extruder 50. On the other hand, raw material that is moist enough to be extruded in the extruder 50 will be highly adhesive, and will thus be difficult to handle outside the extruder 50 (when, for example, conveyed from the mixer 40 to the extruder 50). Adding a second liquid raw material to the raw material in the extruder 50 will therefore allow the moisture of the raw material to be adjusted in the extruder 50, and thus allow the amount of the first liquid raw material that is mixed in the mixer 40 to be lowered. As a result, the raw material in the mixer 40 can be prevented from becoming highly adhesive, thus allowing the raw material to be easily handled when the raw material is fed from the mixer 40 to the extruder 50.

[0103] The second liquid raw material may comprise water. This will allow the amount of the first liquid raw material that is mixed in the mixer 40 to be lowered. As a result, the raw material in the mixer 40 can be prevented from becoming highly adhesive, thus allowing the raw material to be easily handled when the raw material is fed from the mixer 40 to the extruder 50. The second liquid raw material may include one or more selected from the group consisting of water, glycerol, propylene glycol, binder solution, and liquid flavoring.

[0104] In the production method shown in FIG. 3, the powdered raw material preferably includes tobacco, a binder, and an additive. In this case, a powdered raw material and a first liquid raw material are mixed in step S302, thereby allowing tobacco raw materials in which the viscosity has been increased by the binder to be produced. The additive may comprise, 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 additive is included in the powdered raw material to allow the strength of the tobacco sheet to be increased or to allow flavor to be provided.

[0105] The second step (step S302) may comprise separately introducing and mixing each of tobacco, a binder, and an additive with the first liquid raw material in the mixer 40. In this case, the powdered raw materials are separately mixed with the first liquid raw material, thus making it possible to further prevent the powdered raw material from becoming lumpy and allowing the raw materials to be more uniformly mixed.

[0106] In the production method shown in FIG. 3, the first liquid raw material preferably includes an aerosol source, water, and an additive. In this case, the powdered raw material and the first liquid raw material are mixed in step S302, thereby allowing tobacco raw materials in which a greater amount of aerosol is generated to be produced. The aerosol source may comprise, for example, one or more selected from the group consisting of glycerol and propylene glycol. The additive may also comprise, for example, liquid flavoring. The liquid flavoring is included in the liquid raw material to allow the tobacco sheet to be flavored.

[0107] The production method shown in FIG. 3 may comprise, instead of step S305 and step S306, a step in which the raw material mixed in the second step (step S302) is extruded by an extruder 50, and a step in which the raw material extruded from the extruder 50 is formed into a sheet by at least a pair of vertically facing rollers. More specifically, the raw material may be formed in stages into a sheet by three sets of rolling rollers (i.e., six rollers). The production method shown in FIG. 3 may also comprise, instead of step S305 and step S306, a step in which the raw material mixed in the second step (step S302) is extruded by an extruder 50, and a step in which the raw material extruded from the extruder 50 is formed into a sheet by passed through two or more horizontally adjacent rolling rollers. More specifically, the raw material may be formed in stages into a sheet by being passed through each of four horizontally adjacent rolling rollers.

[0108] FIG. 4 is a flowchart of a method for producing a reconstituted pressure-molded tobacco sheet using the mixer 40, the extruder 50, and the die 60 according to a third embodiment. In the method for producing a reconstituted pressure-molded tobacco sheet of the third embodiment, water and a binder are first introduced into a mixer 40 and mixed to allow the binder to swell (first step: step S401). After the first step, a first liquid raw material and a powdered starting material comprising at least tobacco are then introduced into the mixer 40 and mixed with the binder that has been allowed to swell (second step: step S402). Raw material for a reconstituted pressure-molded tobacco sheet is thus produced. The tobacco may be tobacco leaf of any shape, but is preferably tobacco particles that have been classified in the classifier 30 shown in FIG. 1.

[0109] The raw material mixed in the second step is molded into a pressure-molded sheet (molding step). Specifically, the raw material mixed in the second step is fed to the extruder 50 (step S403). The raw material may be highly adhesive, and can therefore be fed by means of a carrier machine such as a belt conveyor to the extruder 50. The raw material fed to the extruder 50 is extruded by the extruder 50 into the form of a sheet. According to the production method shown in FIG. 4, a binder is pre-mixed with water and allowed to swell, and a first liquid raw material and a powdered raw material are mixed while the binding function of the binder is active, thus allowing the viscosity of the raw materials to be increased. As a result, the raw material is easier to handle, and the raw material is also easily extruded by the extruder 50. The viscosity of the raw material is also increased, thus allowing the strength of the tobacco sheet to be enhanced. Specifically, the raw material fed to the extruder 50 is extruded by the extruder 50 into the die 60 (step S405), and is extruded from the die 60 into the form of a sheet (step S406).

[0110] As shown in FIG. 4, a second liquid raw material may furthermore be added to the raw material fed to the extruder 50 (step S404). The raw material must have moisture suitable for the extrusion process in order for the raw material to be extruded in the extruder 50. On the other hand, raw material that is moist enough to be extruded in the extruder 50 will be highly adhesive, and will thus be difficult to handle outside the extruder 50 (when, for example, conveyed from the mixer 40 to the extruder 50). Adding a second liquid raw material to the raw material in the extruder 50 will therefore allow the moisture of the raw material to be adjusted in the extruder 50, and thus allow the amount of the first liquid raw material that is mixed in the mixer 40 to be lowered. As a result, the raw material in the mixer 40 can be prevented from becoming highly adhesive, thus allowing the raw material to be easily handled when the raw material is fed from the mixer 40 to the extruder 50.

[0111] The second liquid raw material may comprise water. This will allow the amount of the first liquid raw material that is mixed in the mixer 40 to be lowered. As a result, the raw material in the mixer 40 can be prevented from becoming highly adhesive, thus allowing the raw material to be easily handled when the raw material is fed from the mixer 40 to the extruder 50. The second liquid raw material may include one or more selected from the group consisting of water, glycerol, propylene glycol, binder solution, and liquid flavoring.

[0112] In the production method shown in FIG. 4, the powdered raw material preferably includes tobacco and an additive. In this case, a powdered raw material and a first liquid raw material are mixed in step S402, thereby allowing tobacco raw materials in which the viscosity has been increased by the binder to be produced. The additive may comprise, 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 additive is included in the powdered raw material to allow the strength of the tobacco sheet to be increased or to allow flavor to be provided.

[0113] In the second step (step S402), the tobacco and additive may each be separately introduced into the mixer 40 and mixed with the binder that has been allowed to swell. In this case, the powdered raw materials are each separately mixed with the binder that has been allowed to swell, thus making it possible to further prevent the powdered raw material from becoming lumpy and allowing the raw materials to be more uniformly mixed.

[0114] In the production method shown in FIG. 4, the first liquid raw material preferably includes an aerosol source and an additive. In this case, the binder that has been allowed to swell, the powdered raw material, and the first liquid raw material are mixed in step S402, thereby allowing tobacco raw materials in which a greater amount of aerosol is generated to be produced. The aerosol source may comprise, for example, one or more selected from the group consisting of glycerol and propylene glycol. The additive may also comprise, for example, liquid flavoring. The liquid flavoring is included in the liquid raw material to allow the tobacco sheet to be flavored.

[0115] In the second step (step S402), the first liquid raw material and powdered raw material may each be separately introduced into the mixer 40 and mixed with the binder that has been allowed to swell. The first liquid raw material and the powdered raw material are each thereby separately mixed, thus allowing the raw materials to be more uniformly mixed. Furthermore, in this case, the first liquid raw material is preferably introduced, prior to the powdered raw material, into the mixer 40 to be mixed with the binder that has been allowed to swell in the second step (step S402). The powdered raw material is thereby introduced and mixed with the binder that has been allowed to swell and the liquid raw material, thus making it possible to prevent the powdered raw material from becoming lumpy and allowing the raw material to be more uniformly mixed.

[0116] The production method shown in FIG. 4 may comprise, instead of step S405 and step S406, a step in which the raw material mixed in the second step (step S402) is extruded by an extruder 50, and a step in which the raw material extruded from the extruder 50 is formed into a sheet by at least a pair of vertically facing rollers. More specifically, the raw material may be formed in stages into a sheet by three sets of rolling rollers (i.e., six rollers). The production method shown in FIG. 4 may also comprise, instead of step S405 and step S406, a step in which the raw material mixed in the second step (step S402) is extruded by an extruder 50, and a step in which the raw material extruded from the extruder 50 is formed into a sheet by being passed through two or more horizontally adjacent rolling rollers. More specifically, the raw material may be formed in stages into a sheet by being passed through each of four horizontally adjacent rolling rollers.

[0117] FIG. 5 is a flowchart of a method for producing a reconstituted pressure-molded tobacco sheet using the mixer 40, extruder 50, and die 60 according to a fourth embodiment. In the method for producing a reconstituted pressure-molded tobacco sheet of the fourth embodiment, powdered raw material including at least tobacco and a first liquid raw material are first introduced into and mixed in the mixer 40 (mixing step: step S501). The tobacco may be tobacco leaf of any shape, but is preferably tobacco particles that have been classified in the classifier 30 shown in FIG. 1. The raw material mixed in the mixing step is then fed to the extruder 50 (step S502). The raw material may be highly adhesive, and can therefore be fed by means of a carrier machine such as a belt conveyor to the extruder 50.

[0118] In the fourth embodiment here, a second liquid raw material is furthermore added to the raw material fed to the extruder 50 (step S503). The raw material extruded from the extruder 50 is molded into a pressure-molded sheet (molding step). Specifically, the raw material fed to the extruder 50 is extruded in the form of a sheet. More specifically, the raw material fed to the extruder 50 is extruded by the extruder 50 into the die 60 (step S504), and is extruded from the die 60 into the form of a sheet (step S505).

[0119] As described above, the raw material must have moisture suitable for the extrusion process in order for the raw material to be extruded in the extruder 50. On the other hand, raw material that is moist enough to be extruded in the extruder 50 will be highly adhesive, and will thus be difficult to handle outside the extruder 50 (when, for example, conveyed from the mixer 40 to the extruder 50). The fourth embodiment thus allows the moisture of the raw material to be adjusted in the extruder, and thus allow the amount of the first liquid raw material that is mixed in the mixer to be lowered. As a result, the raw material in the mixer 40 can be prevented from becoming highly adhesive, thus allowing the raw material to be easily handled when the raw material is fed from the mixer 40 to the extruder 50.

[0120] The second liquid raw material in step S503 may comprise water. This will allow the amount of the first liquid raw material that is mixed in the mixer 40 to be lowered. As a result, the raw material in the mixer 40 can be prevented from becoming highly adhesive, thus allowing the raw material to be easily handled when the raw material is fed from the mixer 40 to the extruder 50. The second liquid raw material may include one or more selected from the group consisting of water, glycerol, propylene glycol, binder solution, and liquid flavoring.

[0121] The mixing step (step S501) may comprise: a first step in which two or more powdered raw materials are introduced into and mixed in the mixer 40; and a second step in which a first liquid raw material is introduced, after the first step, into the mixer 40 and mixed with the powdered raw materials. In this case, the two or more powdered raw materials are mixed in the first step, thus allowing the powdered raw materials to be thoroughly mixed, before the powdered raw material is mixed with the first liquid raw material. In the second step, a first liquid raw material, which is formed by pre-mixing an aerosol source, water, and an additive, may be introduced into the mixer 40. In this case, the aerosol source, water, and additive contained in the first liquid raw material are pre-mixed, thus allowing the powdered raw material and the first liquid raw material to be more uniformly mixed.

[0122] Alternatively, the mixing step (step S501) may comprise: a first step in which a first liquid raw material is introduced into the mixer 40; and a second step in which a powdered raw material is introduced, after the first step, into the mixer 40 and mixed with the first liquid material. In this case, the powdered raw material is mixed with the first liquid raw material, thus making it possible to prevent the powdered raw material from becoming lumpy and allowing the raw materials to be more uniformly mixed. In the second step, tobacco, a binder, and an additive may each be separately introduced and mixed the first liquid raw material in the mixer 40. In this case, the powdered raw materials are separately mixed with the first liquid raw material, thus making it possible to further prevent the powdered raw material from becoming lumpy and allowing the raw materials to be more uniformly mixed.

[0123] Alternatively, the mixing step (step S501) may comprise: a first step in which water and a binder are introduced into and mixed in the mixer 40 to allow the binder to swell; and a second step in which a first liquid raw material and a powdered raw material are introduced into the mixer 40, after the first step, to be mixed with the binder that has been allowed to swell. In this case, a binder is pre-mixed with water and allowed to swell, and a first liquid raw material and a powdered raw material are mixed while the binding function of the binder is active, thus allowing the viscosity of the raw materials to be increased. As a result, the raw material is easily extruded by the extruder 50. The viscosity of the raw material is also increased, thus allowing the strength of the tobacco sheet to be enhanced. In the second step, the tobacco and additive may each be separately introduced into the mixer 40 and mixed with the binder that has been allowed to swell. In this case, the powdered raw materials are each separately mixed with the binder that has been allowed to swell, thus making it possible to further prevent the powdered raw material from becoming lumpy and allowing the raw materials to be more uniformly mixed.

[0124] In the second step, the first liquid raw material and the powdered raw material may also each be separately introduced into the mixer 40 to be mixed with the binder that has been allowed to swell. The first liquid raw material and the powdered raw material are each thereby separately mixed, thus allowing the raw materials to be more uniformly mixed. In this case, the second step may comprise introducing the first liquid raw material, prior to the powdered raw material, into the mixer 40 to be mixed with the binder that has been allowed to swell. The powdered raw material is thereby introduced and mixed with the binder that has been allowed to swell and the first liquid raw material, thus making it possible to prevent the powdered raw material from becoming lumpy and allowing the raw material to be more uniformly mixed.

[0125] The production method shown in FIG. 5 may comprise, instead of step S504 and step S505, a step in which the raw material mixed in the second step (step S502) is extruded by an extruder 50, and a step in which the raw material extruded from the extruder 50 is formed into a sheet by at least a pair of vertically facing rollers. More specifically, the raw material may be formed in stages into a sheet by three sets of rolling rollers (i.e., six rollers). The production method shown in FIG. 5 may also comprise, instead of step S504 and step S505, a step in which the raw material mixed in the second step (step S502) is extruded by an extruder 50, and a step in which the raw material extruded from the extruder 50 is formed into a sheet by passed through two or more horizontally adjacent rolling rollers. More specifically, the raw material may be formed in stages into a sheet by being passed through each of four horizontally adjacent rolling rollers.

[0126] Embodiments of the present invention were described above, but the present invention is not limited to those embodiments, and various modifications are possible within the scope of the technical concept disclosed in the claims, specification and drawings.

[0127] Moreover, any shape or material not directly stated in the specification or drawings is also within the scope of the technical concept of the invention of this application, provided that it exhibits the action and effect of the invention of this application.REFERENCE SIGNS LIST

[0128] 40: Mixer

[0129] 50: Extruder

Examples

Embodiment Construction

[0088]Embodiments of the present invention are described below with reference to the drawings. In the drawings described below, the same or corresponding components are indicated by the same symbols, and will not be described more than once.

[0089]FIG. 1 is a schematic view of a system for producing a reconstituted pressure-molded tobacco sheet. As shown in FIG. 1, the reconstituted pressure-molded tobacco sheet production system 100 comprises: a first grinder 10; a second grinder 20; a classifier 30; a mixer 40; an extruder 50; a die 60; a take-off machine 70; and a dryer 80. In this production system 100, the tobacco is first ground to a predetermined particle size by the first grinder 10. The ground tobacco (tobacco particles) are then ground in a second grinder 20 to a smaller particle size. The tobacco ground by the second grinder 20 is classified by a classifier 30. The tobacco removed by the classifier 30 is again ground in the first and second grinders 10 and 20. The tobacco ...

Claims

1. A method for producing a reconstituted pressure-molded tobacco sheet, comprising:a first step in which water and a binder are introduced into and mixed in a mixer to allow the binder to swell;a second step in which a first liquid raw material and a powdered starting material comprising at least tobacco are introduced, after the first step, into the mixer and mixed with the binder that has been allowed to swell; anda molding step in which the raw material mixed in the second step is molded into a pressure-molded sheet.

2. The method for producing the reconstituted tobacco sheet according to claim 1,wherein the powdered raw material comprises tobacco and an additive.

3. The method for producing the reconstituted tobacco sheet according to claim 2,wherein the second step comprises separately introducing each of the tobacco and the additive into the mixer to be mixed with the binder that has been allowed to swell.

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

5. The method for producing the reconstituted tobacco sheet according to claim 1wherein the second step comprises separately introducing each of the first liquid raw material and the powdered raw material into the mixer to be mixed with the binder that has been allowed to swell.

6. The method for producing the reconstituted tobacco sheet according to claim 5,wherein the second step comprises introducing the first liquid raw material, prior to the powdered raw material, into the mixer to be mixed with the binder that has been allowed to swell.

7. The method for producing the reconstituted tobacco sheet according to claim 1, comprising:a step in which the raw material mixed in the second step is fed to an extruder; anda step in which a second liquid raw material is furthermore added to the raw material fed to the extruder.

8. The method for producing the reconstituted tobacco sheet according to claim 7,wherein the second liquid raw material comprises water.

9. The method for producing the reconstituted tobacco sheet according to claim 1,wherein the molding step comprises:a step in which the raw material mixed in the second step is extruded by means of an extruder into a die; anda step in which the raw material is extruded from the die into the form of a sheet.

10. The method for producing the reconstituted tobacco pressure-molded sheet according to claim 1,wherein the molding step comprises:a step in which the raw material mixed in the second step is extruded by means of an extruder; anda step in which the raw material extruded from the extruder is formed into a sheet by at least a pair of vertically facing rollers.

11. The method for producing the reconstituted tobacco pressure-molded sheet according to claim 1,wherein the molding step comprises:a step in which the raw material mixed in the second step is extruded by means of an extruder; anda step in which the raw material extruded from the extruder is formed into a sheet by being passed between two or more horizontally adjacent rollers.

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