A method and a system of manufacturing a pouch-free oral product, and an oral product and the system

Abstract

A method and a system for making a novel pouch-free oral product, wherein product ingredients by weight percentage are at least: 55-80 % of water, 10 – 25.9 % of filler material, 1 – 5 % of binder agent, 1 – 4 % of taste enhancer, 0.6 – 6.5 % of liquid flavour, 0.2 - 2.1 % of sweetener, 0.02 - 1 % of acidity regulator, and 0.1 – 4 % of liquid active substance. The filler material is at least a micro crystalline cellulose (MCC), the binder agent is at least one of Agar, jelly, biopolymer and a combination of biopolymers, and the liquid active substance is nicotine and / or other active ingredients.

Description

[0001] A method and a system of manufacturing a pouch-free oral product, and an oral product and the system

[0002] The present invention relates to a method and a system of manufacturing a pouch-free, oral product, an oral product and the system, as defined in the preamble of the attached independent claims.

[0003] Background of the invention

[0004] Ever since the authorities in Scandinavia started to tax smoking tobacco centuries ago, it has stimulated the usage of non-smoking tobacco products, like Chewing tobacco and Snus style products.

[0005] A traditional Snus is made of Tobacco, Salt, Water and often some kind of pH buffering agent such as initially different types of ashes, and later carbonates like sodium bi-carbonate.

[0006] In the early 20thcentury, the tobacco industry in Scandinavia was monopolized and controlled by the governments, inter alia to ensure proper tax collection. Up until the early 1970's the only product format for Snus was in loose form. Svenska Tobaksaktiebolaget AB (later Swedish Match AB) presented the first real innovation to Snus back in the 1970’s and that was defined or named as a Portion Snus. Basically, it was the same “Loose Snus” as before, but was dryer so that it could be packed as a free-flowing powder in a small teabag like pouch as individual portions. To achieve the same moisture, these individual portion pouches were then sprayed all-over with water to reach its final product moisture.

[0007] The new convenient “Portion Snus” not only contributed to the renaissance for Snus as a category, but also grew in popularity to the extent that it overtook the market from “Loose Snus” in the early 2000 's.

[0008] A second innovation (also made by Swedish Match AB) launched in the early 2000’ s implied making pellets, including all the moisture to be therein, based on “Loose Snus” and flow-pack these into portions enclosed by non-woven material. That second invention was which was called “White Snus” gave productivity gains, and was marketed as a more white and hygienic format. The “White Snus” product appeared whiter to the consumer before use, but turned brown as any other Snus after use. In general, any brown, tobacco based Snus style products as e.g. referred to above, yield: a) a brown appearance; b) a risk of discolouring of the teeth of the consumer over time; c) a risk of causing caries on the teeth and a bad breath due to containing a few percent of sugar; d) a manure-like aroma and taste experience as the product is tobacco based and contains ammonia, which is not very well appreciated by consumers from countries outside the Nordic countries; e) health-risk substances by virtue of the product being tobacco based , implying that it contains not only nicotine, but also TSNA's (Tobacco Specific NitrosAmines) which are carcinogenic, in addition to containing at least traces of heavy metals, pesticides, herbicides and a number of other volatile substances originating from the processes of drying, curing and handling the tobacco like many grown agricultural plant materials; f) careful and complex raw tobacco selection and a complex heat treatment process using heating, direct steam treatment, ventilation and cooling etc., g) an average nicotine delivery upon use by the consumer of approx. 30% over a consumption cycle of 30 minutes, caused by the nicotine being naturally bound in the cellular structure of the tobacco; and h) an average shelf-life, under refrigerated conditions, in the range of 20-28 weeks for any brown type of snus products on the market today.

[0009] In 2014 the first “All White Snus” products entered the markets in Sweden and Norway. It was developed and brought to the market by a small Swedish company called Winnington AB. It really implied a paradigm-shift product, and the product appeared to very disruptive in the snus market, mainly because: i) it had and opaque white appearance and remained white; j) it did not cause any discolouring of the teeth of the consumer; k) it had no sugar-based sweeteners or mouth fermentable starches, thereby causing no risk for caries or negative oral hygiene impacts; l) it had Xylitol with similar dental effects as from chewing gums; m) it contained no naturally occurring ammonia, unless added to boost specific flavours; n) it did not contain any unwanted compounds, nor traces of heavy metals, pesticides etc., thus meeting requirements of food or pharma approved ingredients; o) its main ingredients were typically water, cellulose (MCC), Salt, Xylitol, non-sugar sweeteners, flavourings, pH-buffers (bicarbonate) and added pharmaceutical grade liquid nicotine, extracted from tobacco; p) it required no heat treatment due to built-in purity and hygiene standards of the ingredients; thus in a far simpler manufacturing process; q) it had a faster nicotine release and higher average nicotine yield over 30 minutes consumption cycle, due to the nicotine being more readily available in the product; r) it had an increased shelf life of about 12 months at ambient conditions, implying no refrigeration needed; s) the product could be entirely tobacco free, merely containing the nicotine thereof; and t) it yielded only Portion Pouched products as such, implying no “loose product” variant.

[0010] As regards s) above, the “All White Snus” product rounds an EU snus ban, Sweden having been the only country excluded therefrom. The tobacco free product can, on the contrary today be sold in most countries outside Sweden and also in many European countries. However, the “All White” snus product could contain tiny amounts of tobacco if required for legislative reasons like in Norway, to thereby meet the requirements of current tobacco product regulations.

[0011] In summary, a next generation product with the benefits of a white appearance, free from unwanted compounds and retail store stable at room temperature, also enabled a very clear and clean flavour experience, thereby opening up for new possible flavour categories, such as e.g. fruit, mint etc, that previously didn't work well at all with the salty, ammonia brown tobacco base character. This altogether opened up for market acceptance and consumer appreciation outside of Scandinavia geographically, and new segments as a now viable alternative also for cigarette smokers.

[0012] Prior art

[0013] In the patent literature CA2, 918, 271-Al, EP 3,440,945-Al and US 11,517,566-B2 disclose some typical oral products related to “all white” types of snus. of the invention

[0014] The present invention has an object to manufacture “all white” oral products of the kind mentioned in the introduction, and thereby avoiding the use of a pouch enclosing the product, while maintaining some of established features and also presenting an array of novel features with regards to manufacturing method, manufacturing system and product features.

[0015] In early 2023, the applicant considered it was time for a next step in the evolution of the current product category. The subject product of the current invention comes with the following USP's over the just mentioned prior art All-White products above.

[0016] Thus, some of the objects of the invention are:

[0017] To provide a pouch free product, implying that the non-woven pouch material which has so far formed and enclosed the product portion, is no longer needed. It should be recalled that any current non-woven fleece material contains about 30-40% plastic binder in order to be heat sealable to weld the pouches. Without a pouch it is intended to provide on the market a first portioned oral nicotine product / snus that is entirely plastic free. Providing a plastic free property of the product enables biodegradability, which is environmentally important.

[0018] - Further, it is intended by the invention to manufacture a product which is entirely biodegradable based, implying that it disintegrates in its existing components over time by weather or mechanical exposure. Thereby, it is intended to resolve the growing problems experiences with used snus-bags thrown on the ground in the cities and nature, like unwanted disposal habits as regards cigarette butts and chewing gums. Still further, it is an object of the invention to resolve likewise growing problems in municipal waste water treatment plants, where the non-woven pouch material today causes clogging of the fine filters of the treatment plants.

[0019] Without the barrier of a pouch, the new invention product also comes in direct contact with the oral mucosa / gum. This allows a better nicotine and flavour experience.

[0020] Another object is to create a new product which is also pressure sensitive, so that it releases an active substance, e.g. nicotine, and it's flavours with a combination of capillary force effects (like in any snus), but also by pressure exposure. A further object is to create significant productivity gains related to manufacturing of the invented, novel product, not only as regards portions per minute related to invested capital in manufacturing system, but also the desirability that no pouch is needed to enable a faster way of manufacturing and thereby lower production cost, also due to no pouch fleece material being required. This enables almost complete freedom in regard to product portion shape and format.

[0021] An object of the invention is also a desire to easily provide any product with a surface pattern to leverage and vary the aesthetic appearance and allowing a means of communication to the end user, such as e.g. product identity. This is particularly important given that all pouched products today looks very much the same. In fulfilling the object of providing a surface pattern, it is intended to enable altering of a mechanical friction coefficient of the product, so that it will feel less slippery in mouth.

[0022] Among still further objects of the invention are to enable adjustment of total contact surface area, i.e. towards the mucosa / gum to alter taste / stimulus uptake from the product, and also to create a “suction effect or vacuum cup effect” by creating small perforated holes in the contact surface on the product, working similarly to the pores in a winter friction tyre (without spikes).

[0023] Finally, it must be observed that the invention intends to improve consumer productsatisfaction. Amain reason for consumer complaints is that in prior art snus / all-white products, the enclosing pouches are broken or exhibit bad welds. The pouches normally have one longitudinal weld and two transversal welds. Such complaint reasons normally represents 65-75% of the total number of complaints. Furthermore, the pouch-free object of the invention removes a most annoying experience of new snus / all-white users related to the discomfort of the transversal welds, implying sharp corners itching, and irritating attempts to manually fold the welds away etc.

[0024] Summary of the invention The novel and characteristic features of the present invention related to the method and the system of manufacturing a pouch-free oral product, the oral product and the system, are defined in the attached independent claims and their associated sub-claims, respectively.

[0025] Fig.l shows a simplified flow-chart showing major steps in manufacturing the novel oral product.

[0026] Fig. 2a shows from one end in a perspective view a first novel system for making a stepwise manufacturing of batches of the novel oral product;

[0027] Fig. 2b shows the first novel system of Fig. 2a from another end thereof;

[0028] Fig. 2c shows as an enlarged view of a non-limiting version of a controller station of the system as shown on Figs.2a and 2b and labelled as lie on Fig. 2b;

[0029] Fig. 2d shows an enlarged detailed view at lid on Fig. 2a;

[0030] Fig. 2e shows an enlarged detailed view from below at He on Fig. 2a;

[0031] Fig. 2f shows an enlarged detailed view at Ilf on Fig. 2a; and

[0032] Fig. 2g shows an enlarged detailed view at Ilg on Fig. 2a.

[0033] Fig. 3a shows from one end in a perspective view a second novel system being a variant of the first novel system for manufacturing batches of the novel oral product in a continuous process;

[0034] Fig. 3b shows the first novel system of Fig. 3a from another end thereof;

[0035] Fig. 3c shows as an enlarged view of a non-limiting version of a controller station of the system as shown on Figs.3a and 3b and labelled as IIIc on Fig. 3b; Fig. 3d shows an enlarged detailed view at Hid on Fig. 3a;

[0036] Fig. 3e shows an enlarged detailed view from below at Hie on Fig. 3a;

[0037] Fig. 3f shows an enlarged detailed view at Ulf on Fig. 3a; and

[0038] Fig. 3g shows an enlarged detailed view at Illg on Fig. 3a.

[0039] Fig. 4a shows from one end in a perspective view a second novel system being a variant of the first novel system for manufacturing batches of the novel oral product in a continuous process;

[0040] Fig. 4b shows the third novel system of Fig. 4a from another end thereof;

[0041] Fig. 4c shows as an enlarged view of a non-limiting version of a controller station of the system as shown on Figs.4a and 4b and labelled as IVc on Fig. 4b;

[0042] Fig. 4d shows an enlarged detailed view at IVd on Fig. 4a;

[0043] Fig. 4e shows an enlarged detailed view from below at IVe on Fig. 4a;

[0044] Fig. 4f shows an enlarged detailed view at IVf on Fig. 4a; and

[0045] Fig. 4g shows an enlarged detailed view at IVg on Fig. 4a.

[0046] Fig. 5 shows a non-limiting selection of embossing patterns available to a top face of the product when in a mould space.

[0047] Fig. 6 shows as a non-limiting example how embossing patterns could be deployed in mould spaces of a mould tray.

[0048] Fig. 7 shows as a non-limiting example how embossing patterns could be deployed in mould spaces of a continuous mould belt. Detailed

[0049] The method of manufacturing the pouch-free oral product is now initially to be described with reference to Fig.l

[0050] In a dryblending step al) there is mixed in a first mixer device 103 dry powder ingredients 101; 102 of the product into a powder premix 104. The powder premix 104 contains micro crystalline cellulose (MCC) powder or chemical pulp powder as filler agent 101, sodium chloride as a taste enhancer, sodium bicarbonate as an acidity regulator, and e.g. acesulfame K (AceK) and / or xylitol as a sweetener agent, plus optionally tobacco powder (if at all required), all in common labelled as 102. MCC is manufactured by treating high quality / purity dissolving pulps chemically in a crystallization process, breaking down fibers into its particulate and crystalline form.

[0051] These ingredients 101; 102 are typically weighed up on a scale in their individual proportions according to the specific recipe and put into the mixer 103, and mixed until homogenously blended.

[0052] In a non-limiting aspect, appropriate mixer types are obvious to an expert in the art. Suitably, but not necessarily, a mixer could at least include high speed knife mixers and twin shaft counter rotating paddle blenders, however their complexity to a large extent being dependent on the level of industrialized manufacturing. A suitable, though non-limiting mixing time could be in the range 1-3 minutes.

[0053] In a pre-wetting step a2) there is added water 105 to the powder premix 104 while it is located in a second mixer 106 so in a mixing therein to evenly distribute the water into the powder premix 104 to yield a wetted powder premix 104’.

[0054] It will be appreciated that a part of total water to be used in the overall process is weighed up on a scale according to the specific recipe and poured into the mixer 106 while mixing. This takes place until the water 105 is evenly distributed within the dry premix 104. Such water addition can take place in different ways depending on a selected type of mixer 106 and its mixer size. It is conceivable, though yet not to be construed as limiting the invention, that water can be poured into small size mixers 106 by hand, but over-sprayed using a pressure vessel and integrated spraying nozzles when using a bigger type of mixer 106. Atypical suggested, yet not a limiting mixing time range could be 1-3 minutes.

[0055] In a preparation step bl) there are in a substep bli) entered pre-determined liquid amounts of liquid flavours 108 and liquid active substance 107 into a common mixer jar 109, and there are in a substep blii) entered a pre-determined amount of water 110 and a binder agent 111 in powder phase into a boiling-type vessel 112 while stirring. The liquid flavours 108 and liquid active substance(s) 107 are suitably weighed up on a scale in their individual proportions according to the specific recipe and put in the same common mixer jar 109. The water 110 is weighed up on a scale in the right proportion according to the specific recipe and put into its own boiling vessel 112. The powdered dry binder agent 111 is weighed up on a scale in the right proportion according to the specific recipe and put into the same boiling vessel 112 as the water is entered, while stirring. The liquid active substance(s) 107 could be nicotine and / or other active ingredient selectable e.g. from one or more of: vitamins, minerals, antioxidants, caffeine, terpenes, phytoncides, and amino acids.

[0056] Further, the powdered dry binder agent 111 could be one or more of: Agar, jelly, biopolymer and combinations of biopolymers.

[0057] In a heating step b2) the boiling vessel 112 is heated while stirring the mixture of the water 110 and the binder agent 111 until the mixture reaches a boiling state (approx. 102°C). Suitably, the mixture could be allowed to boil at the boiling state for a short time period, e.g. approximately in the range 1 -10 minutes, or less, e.g. 1 - 5 minutes. Such limited time boiling could be suitable to enhance the binder agent 111, e.g. Agar. The heating is then terminated and the mixture is allowed to cool until a first set temperature Tl. The liquid amounts in said mixer jar 109 are then poured into the mixture in the vessel 112 while stirring. Tl is typically in the range of about 35°C -70°C, or in some cases about 50°C -70°C. Due to the fact that some types of liquid flavours 108 are quite volatile in nature, a lower range of the temperature Tl in the vessel 112 could be of advantage before the mixture of liquid active substance(s) 107 and the liquid flavour(s) 108 is added to the vessel 112.

[0058] The mixture of the liquid active substance(s) 107 and liquid flavour(s) 108 is suitably poured, sprayed and / or dosed from the mixer jar 109 into the water 110 and binder agent 111 mixture solution in the vessel 112 under stirring. Such dosing can be done by hand at small scale production, but automatically dosed when operating at industrial scale. Time used depends on how the heating and cooling of the vessel 112 operates.

[0059] The boiling vessel 112 can be replaced by an industrial cooker with integrated heating / cooling properties if large volume manufacturing is intended.

[0060] In a powder premix adding step c) upon the mixture temperature of step b2) being at a value below said first set temperature Tl, the powder premix 104 of step al) is entered in the prewetted state 104’ from the mixer 106 into the heating vessel 112 of step b2) while stirring to yield a product composition 113. When the temperature in the vessel 112 is below a lowest value of Tl, such as e.g. below 60°C, but suitably above 50°C, the pre-wetted powder mix 104’ is dosed into the liquid mixture in the vessel 112 under stirring, as indicated. The dosage operation of the pre-wetted powder mixture 104’ into the vessel 112 can be done manually or automatically. Atypical time used for such operation could e.g. be 1-3 minutes.

[0061] In a moulding step d) of the product when the temperature in the vessel 112 is above a second set temperature T2 being lower than the first set temperature Tl, the product composition 113 from the vessel 112 is entered or poured into at least one mould 114; 135. Suitable, the mould comprises a plurality of mould spaces 114’; 136, such as pockets or recesses. With the temperature T2 e.g. above 43°C, the complete blend or composition 113 is poured / dosed into the spaces 114’; 136 of the mould 114; 135 either manually, semi -manually or by use of an automated dosing / filling equipment 115. When the moulding spaces 114’ are filled with the composition 113, the dosing into each such space 114’; 136 could be in an exact pre-set amount, or any surplus blend / composition 113 could be removed, e.g. by scraping off for recycling of the removed amount. Filling time of e.g. a tray 114 of 70 mould spaces 114’ could consume about 1-2 minutes using proper filling machinery 115.

[0062] In a cooling step e) the product composition 113 located in said spaces 114’; 136 of the at least one mould 114; 135 is allowed to cool down, suitably in a designated cooler 116 to a temperature below a third set temperature T3. In a non-limiting example T3 is 20°C. Suitably, the cooling could be done in a refrigerator for small scale or test manufacture. In an industrial scale manufacturing an inline cooling tunnel 116 is suitably used. Suitable cooling time could be 1-2 minutes, although it will be appreciated, at least in a continuous manufacturing process that velocity of the mould 114; 135 past a filling station 115 will dictate and must match speed of moulds 114; 136 through the cooler 116.

[0063] In a clearing step f) the moulded oral products when stabilized after cooling are removed from the at least one mould and the oral products 117 made from the product composition 113 and still in their respective mould space 114’; 136 of the mould are delivered to a product exit 118 to be released from the mould spaces 114’; 136 for subsequent packaging. Emptying the oral products 117 from the at least one mould 114; 135 could be done manually or by automated means in a line. If the mould is of a flexible material, mere passing of the mould over a roller having a small radius of curvature could trigger the oral products to pop out from their mould spaces 114’; 136, respectively. Atypical time duration of emptying a tray having e.g. 70 product cavities could be approx. 1- 2 minutes, depending on speed of the moulds 114 through the filler station 115 and the cooler 116. Atypical time duration of emptying a portion of the mould belt 135 having e.g. 70 product cavities could similarly be approx. 1- 2 minutes, depending on speed of the mould belt 135 through the filler station 115 and the cooler 116.

[0064] Any downstream packaging method is dictated by the chosen consumer required packaging in scope. Thus, packaging of the oral products can be fully automated and packed into boxes, cans, bags, sachets, blisters etc. and involves commonly available industrial packaging equipment (not shown).

[0065] Suitably and related to step e), at least one surface region of the moulded oral product(s) could be provided with a surface treatment comprising at least one of: corrugations, indentations, protrusions and knobs. At least part of the surface treatment could be made by use of a complimentary configuration on e.g. a bottom face of a mould space 114’; 136 where a respective product is moulded.

[0066] An upper surface region of the moulded oral product while still in the mould space could be subjected to an action from surface treatment device 119, such as a stamping device 119’ (see Figs. 2a and 2b) or an embossing device 119” (see Figs. 3a and Fig. 3b). With respect to surface treatment from a bottom face of the mould space 114’; 136, the treatment could be presented as at least one of letter, numeral and / or figure. Such type of treatment could also be obtainable on the upper surface region using the stamping device 119’. Aspects of such surface treatment will be more appreciated from studying Figs. 2a-2g and Figs.3a-3g and the associated detailed description.

[0067] Suitably in the product composition of step c) the weight percentages contributed by the powder premix 104 are: 10 -25% of the filler agent, 1 - 4 % of the taste enhancer, 0.01 - 2 % of the acidity regulator, and 0.2 - 2.1 % sweetener agent.

[0068] If tobacco is required due country legislation and / or customer demands, the powder premix 104 could further contain as additional filler agent a tobacco powder in the amount of 0.0001 - 0.9 % by weight of the product composition.

[0069] The total amount of water 105 and 110 supplied in steps a2) and bl.ii), respectively is suitably 55 - 80 % by weight of the product composition 113 of step c). Further, with reference to step bl.i) the amount liquid flavours 108 are in the range of 0.6 - 6.5 % by weight of the product composition of step c), and the amount of liquid active substance(s) 107 is the range 0.1 - 4 % by weight of the product composition of step c). Still further, in step bl.ii) the amount of binder agent in powder phase is suitably 1 - 5 % by weight of the product composition 113 of step c).

[0070] Although not a precondition for the method of manufacturing the oral product, plant fibers or starch fibers could be added into the vessel 112 in step c) in the process of stirring to yield the product composition 113. However, the amount of the fibers should be less than 10% by weight of the product composition 113. Such plant fibers should be non-tobacco fibers selected from one or more of natural untreated starches, bamboo fibers, softwood dissolving fibers, hardwood dissolving fibers, wheat fibers, rye fibers, oat fibers, barley fibers, flax fibers, hemp fibers, apple fibers, citrus fibers, and / or other fruit fibers.

[0071] Within the concepts of the invention, it is also conceivable to add at least one non-tobacco water-soluble substance to the premix 104 in step al). Such at least one added substance is suitably selectable from one or more of: vitamins, minerals, antioxidants, caffeine, terpenes, phytoncides, and amino acids.

[0072] It is also conceivable as an option within the concepts of the invention to add and stir into the liquid amount in the mixer jar 109 in step bl.i) at least one non-nicotine material, e.g. a mineral material selected from one or more of perlite, vermiculite, calcium phosphate, silicon dioxide and egg shells.

[0073] Thus, the present invention provides for a pouch-free, mouth non-soluble, oral product as manufactured according to the method as described above and using equipment to be more closely described in the subsequent sections of the detailed description with reference to the associated drawings.

[0074] In summary, the oral product ingredients by weight percentage are at least: 55-80 % of water 105; 110, 10 - 25.9 % of filler material 101, 1 - 5 % of binder agent 111, 1 - 4 % of taste enhancer 102, 0.6 - 6.5 % of liquid flavour 108, 0.2 - 2.1 % of sweetener 102, 0.02 - 1 % of acidity regulator 102, and 0.1 - 4 % of liquid active substance 107. The filler material is at least a micro crystalline cellulose (MCC) powder or chemical powder material. Further, the binder agent is suitably one or more of Agar, jelly, biopolymer or a combination of biopolymers, and the taste enhancer is suitably sodium chloride.

[0075] Still further, the liquid flavour is a single- or multi-component liquid. The sweetener is a single- or multi-component powder, the acidity regulator is suitably sodium bicarbonate, and the liquid active substance is nicotine and / or other active ingredient(s). If the sweetener 102 is a two-component powder, one component by weight is suitably less than ’A by weight of the other component. The optional other active ingredient is selectable from one or more of: vitamins, minerals, antioxidants, caffeine, terpenes, phytoncides, and amino acids. If tobacco material is required to be added to the product, either due to legislation in countries where the oral product is marketed and / or due to customer requirements, the premix 104 may further comprise such additional dry powder ingredient 102 in the form of tobacco powder in the amount of 0.001-0.9% by weight of the product composition 113.

[0076] It will be appreciated that surface treatment of the oral product 117 by means of the treatment device 119; 119’; 119” as described will enhance consumer satisfaction of the product by the provision of at least one of corrugations, indentations, protrusions and knobs and / or at least one of letter, numeral and / or figure on one or more product surfaces, due to the oral product in a better way not able to move about between the lip and teeth to the same extent as if the surfaces of the oral product were made smooth. Thus, as indicated as one of the objects of the invention, the invention will through the surface treatment enable adjustment of total contact surface area of the oral product, i.e. towards the mucosa / gum to alter taste / stimulus uptake from the product, and also to create a “suction effect or vacuum cup effect” by creating small perforated holes in the contact surface on the product.

[0077] The present invention provides for a manufacturing of an ’’all white” oral product having materials and properties which substantially depart from those of the prior art. Anon- exhaustive listing of differences of the invention is:

[0078] The liquid nicotine or active ingredient 107 does not require dilution with any solvent, nor any mixing at the mixer jar 109 with cellulosic fibers, as the liquid nicotine 107 and liquid flavour 108 are mixed with water 110 and binder agent 111 in the heated mixer vessel 112.

[0079] - Nicotine is not bound into any product ingredient pores. The ready-made product yields an open porous structure, holding the water, nicotine and flavour in a spongelike void structure, and hence nicotine is not particularly bound to any other ingredient.

[0080] In the present invention suitably pharma grade nicotine is used (> 99.95% purity).

[0081] In the process of arriving at the final product no equilibrating steps are required, nor is use of any type of chewing gum base required in product.

[0082] Compression moulding or moulding by extrusion is avoided, and moist mixture pretreatment in the vessel 112 is applied.

[0083] The product has a high water percentage in the range of 55 - 80% or 60 - 80%, and low filler percentage in the range of 10 -25 %,

[0084] Above all, the oral product is pouch-free and the product matrix as such is not mouth soluble.

[0085] The invention is now to be further described with reference to Figs. 2a - 2g and Figs. 3a - 3g illustrating a first and a second embodiments of equipment for the manufacturing of the oral product 117, respectively. It will be noted that the second embodiment as shown on Figs. 3a - 3g has most components identical to components of the first version on Figs. 2a - 2g, apart from different types of surface treatment device 119’ and 119” being present for the first and second embodiments, respectively. Accordingly, the discussion of Figs. 3a - 3g will merely focus on the differences and related structural impacts and consequences for the end product 117 As indicated by section lie, Fig.2c shows a controller station 120 having a hopper 121 for the product composition 113 to enter the station 120 and to be fed to an array of filling nozzles 122. It will be appreciated that the hopper 112 could be replaced by e.g. a feeder screw (not shown). Further, the station can have a control panel 123. Intermittent or continuous output of product composition from the filling nozzles 122 may be controlled from settings on the control panel 123. A mould tray 114 having as a non-limiting example 10x7 mould spaces 114’ is shown entering the controller station 120 and the station 120 may be equipped with a first conveyor 124 to move the mould tray 114 through the station 120 past the filler nozzles 122 and onto a second conveyor 125 driven by a motor 126, either for continuous movement of the conveyor 125 or intermittent movement or other selectable type of movement. It is noted from section lid and related Fig. 2d that the mould spaces 114’ at their bottom may exhibit a selectable pattern 114” from which the oral product 117 will receive a complimentary pattern of on a face thereof. <

[0086] After the filled tray 114 enters the conveyor 125 it may pass directly to the cooler 116 or stop for a short moment at a surface treatment device 119’ comprising a controllable pusher device 127, e.g. a solenoid 127 and a stamp plate 128 having on its lower side face a plurality of stamp patterns 129 as shown on Fig. 2e. If the filled tray 114 is stopped at the device 119’, its proper location to match the stamp plate 128 can be determined by an alignment sensor 130 which contributed to cause the second conveyor 125 to be stopped until surface treatment by stamping action has been effected. The upper face 117’ of the filled mould spaces 114’ prior to stamping are indicated by section Ilf and the related Fig. 2f.

[0087] After completed stamping action by the pusher device 127 and the stamp plate 128, the conveyor moves the filled and stamped tray 114 with its oral surface treated products 117 therein through a cooler 116 being of a cooling channel type. In order to control and monitor the cooling temperature therein, temperature sensors 131 may be located on the cooler housing.

[0088] Subsequent to leaving the cooler 116, the individual oral product 117 are released from the tray 114, e.g. by bending the tray 114 over the curved end 125’ of conveyor 125 or by other procedure (not shown). The upper stamped face 117” of the oral product 117 is indicated by section Ilg and Fig. 2g. The second embodiment of the manufacturing equipment as shown on Figs. 3a - 3g does not require any intermittent stop of the conveyor 125 in order to surface treat an upper face 117’ (see section Ilf and Fig. 2f and the section Ilf on Fig. 3a. By using the surface treatment device 119” instead of the device 119’ on Fig. 2a, a continuous movement of the conveyor 125 is possible. The device 119” comprises a rotary roller 132 having a plurality of circumferential patterns 133 thereon as shown more clearly on Fig. 3e with reference to section Hie. After having passed the device 119”, the upper face 117’” will suitably have a stripe pattern as indicated by sections Ulf and Illg and the corresponding Figs. 3f and 3g.

[0089] However, each circumferential ring pattern could alternatively be a circumferential array of short stripes oriented in a longitudinal direction of the roller 132 or a circumferential array of symbols or letters or numerals. It would also be possible to have the entire surface of the roller covered by a pattern uninterrupted by empty interspaces 134. Such pattern should be design so as to ensure a representative embossing on the face 117’ of the oral product. It should be observed that the rotary velocity of the roller 132 should match the movement velocity of the conveyor 125, so that the roller 132 does not act as a movement retarder or accelerator on the filled tray 114 relative to its normal movement by the conveyor 125, nor causes the tray 114 to accidentally thereby shift direction on the conveyor 125.

[0090] The invention is now to be further described with reference to Figs. 4a - 4g illustrating a third embodiment of equipment for the manufacturing of the oral product 117.

[0091] It will be noted that the third embodiment as shown on Figs. 4a - 4g has some components identical to components of the first and second versions on Figs. 2a - 2g and 3a - 3g. It will, however, be noted that the mould trays 114 on the conveyor 125 have been replaced by continuous array of mould trays 114 effectively forming a continuous belt 135 of transversely extending parallel rows of mould spaces 136.

[0092] As indicated by section IVc, Fig. 4c shows the controller station 120 having the hopper 121 for the product composition 113 to enter the station 120 and to be fed to an array of filling nozzles 122. As indicated earlier, the hopper 112 could e.g. be replaced by a feeder screw (not shown). Further, the station 120 can have the control panel 123. Intermittent or continuous output of product composition from the filling nozzles 122 may be controlled from settings on the control panel 123. As seen from Figs. 4a and 4b there could e.g. be 10 mould spaces 136 in each transverse row of such spaces on the belt 135. However, the number of spaces 136 is each such row is of course not limited to 10.

[0093] Feeding into the transverse rows of spaces 136 from the filling nozzles 122 could be an intermittent or continuous operation. If intermittent, then the speed of the belt 135 should be adjusted to avoid spillage of product composition 113 at interspaces between the spaces 136. Continuous feeding from the nozzles 122 would likely yield spillage at least at interspaces between the transverse parallel rows of mould spaces 136. In order to remedy this rather unwanted, yet unavoidable spillage, a plow shaped scraper 137 is arranged downstream of the station 120 to overlie on the belt 125 to scrape off excess product composition 113 in order to have it recycled to be re-entered in due course into the hopper 112 or screw feeder and exit through the nozzles 122.

[0094] As seen from Figs. 4a and 4b, downstream of the scraper 137 there is located the embossing device 119” of Figs. 3a and 3b, comprising the rotary roller 132 having a plurality of circumferential embossing patterns 133 thereon as shown more clearly on Fig. 4e with reference to section IVe. The patterns 133 may be spaced by interspaces 134. Prior to passing the device 119” the moulded product 117 will have no embossed pattern 117’ thereon, as indicated by section IVf and the corresponding Fig.4f. After having passed the device 119”, the upper face of the moulded product 117 will be embossed, in the non-limiting example suitably by getting a stripe pattern 117”’ as indicated by section IVg and the corresponding Fig. 4g.

[0095] In Figs. 2a - 2g and 3a - 3g there is a first conveyor 124 which is not required in the embodiment of Figs. 4a - 4g. However, the belt 135 is suitably driven by the motor 126 via a drive roller 138 in cooperation with a ’’turn-around” roller 138’ at the other end of the belt 135. Similar rollers 138; 138’ are also indicated on Figs. 2a - 2b and 3a - 3b for driving the conveyor 125.

[0096] It is noted from section IVd and related Fig. 4d that the mould spaces 136 at their bottom may exhibit a selectable pattern 136’ which the oral product 117 will receive a complimentary embossed pattern of on the bottom face thereof in the mould space 136. Downstream of the embosser 119” with the embossing roller 132 with the pattern 133, the plurality of transverse parallel rows of filled mould spaces 136 suitably may pass directly into the cooler 116 being of a cooling channel type. In order to control and monitor the cooling temperature therein, temperature sensors 131 may be located on the cooler housing, as previously explained.

[0097] Subsequent to leaving the cooler 116, the individual oral products 117 are released from the belt 135 of mould spaces, e.g. by bending the belt 135 as indicated by its curved end 135’ of the belt 135 when it passes over the roller 138 or by other procedure (not shown). The upper embossed face 117”’ of the oral product 117 is indicated by section IVg and Fig. 4g.

[0098] However, each circumferential ring pattern 133 could alternatively be a circumferential array of short stripes oriented in a longitudinal direction of the roller 132 or a circumferential array of symbols or letters or numerals. It would also be possible to have the entire surface of the roller covered by a pattern uninterrupted by empty interspaces 134. Such pattern should be designed so as to ensure a representative embossing on the face 117’ of the oral product 117 facing upwards in the mould space 114’; 136.

[0099] Some non-limiting examples of top face embossing are shown on Fig. 5. Fig. 5a indicates that the product top face 117’ has no embossing. Fig. 5b indicated a zig-zag embossment 117” possible to make using the embossing device 119’ or 119”. The previously shown embossment 117’” on Fig. 5c is most suitably made using the device 119”. The embossments 117”” on Fig. 5d and 5e may be a challenge to align perfect on the top of the product 117 using the roller type of device 119”, and likely more suitable for making with a stamp type of device 119, 119’ as shown on Figs. 2a and 2b. An embossment type 117”” as shown on Fig. 5f could however be suitably made using the device 119’ or 119”.

[0100] Suitably, the embossing part of the device 119’ or 119” could have a matching surface temperature to enable a non-stick property when contacting the product 117 prior to its passing into the cooler 116.

[0101] It should be observed that the rotary velocity of the roller 132 should match the movement velocity of the conveyor 125 or the belt 135 so that the roller 132 does not act as a movement retarder or accelerator on the filled tray 114 relative to its normal movement by the conveyor 125, nor make a mess out of the embossing action, nor causes the tray 114 to accidentally thereby shift direction on the conveyor 125. Similarly, with the mould space belt 135, the movement speed thereof should match the rotational speed of the roller 132 to avoid that the embossing pattern 133 on the roller 132 destroys the product top surface instead making the desired embossed pattern.

[0102] As indicated on Figs. 6 and 7, it will be appreciated that the bottom of the mould spaces 114’ on the mould tray 114 and on the bottom of the mould spaces 136 on the mould belt 135 offer a greater variety of possible embossment patterns 114”; 136’ .

Claims

CLAIMS1. A method of manufacturing a pouch-free oral product, the method comprising:- al) in a dryblending step: mixing in a mixer device (103) dry powder ingredients (101; 102) of the product into a powder premix (104),- a2) in a pre-wetting step: adding water (105) to the powder premix (104) while mixing to evenly distribute the water into the powder premix (104) to yield a wetted powder premix (104’),- bl) in a preparation step: bli) entering pre-determined liquid amounts of liquid flavours (108) and / or liquid active substance(s) (107) into a common mixer jar (109), and blii) entering a pre-determined amount of water (110) and a binder agent (111) in powder phase into a boiling-type vessel (112) while stirring,-b2) in a heating step: heating the boiling vessel (112) while stirring the mixture of the water (110) and the binder agent (111) until the mixture reaches a boiling state, then terminating the heating after boiling and allowing the mixture to cool until a first set temperature (Tl), and then adding the liquid amounts (107, 108) in said mixer jar (109) into the mixture in the vessel (112) while stirring,-c) in a powder premix adding step: upon the mixture temperature of step b2) being at a value below said first set temperature (Tl), delivering the wetted powder premix (104’) of step a2) into the vessel (112) of step b2) while stirring to yield a product composition (113), -d) in a moulding step of the product: when the temperature is above a second set temperature (T2) being lower than the first set temperature (Tl), entering the product composition (113) into at least one mould space (114’; 136) of a mould (114; 135), -e) in a cooling step: subjecting the product composition (113) located in said at least one mould space (114’; 136) to cooling down to a temperature below a third set temperature (T3), and-f) in a clearing step: removing the oral product(s) (117) from said at least one mould space (114’; 136) and delivering the oral product(s) made from the product composition to a product exit.

2. The method of claim 1, wherein the liquid active substance is nicotine.

3. The method of claim 1, further wherein in step e) at least one surface region of the oral product(s) being provided with a surface treatment comprising at least one of: corrugations, indentations, protrusions and knobs.

4. The method of claim 3, wherein at least part of the surface treatment is made by use a complimentary configuration (114”) of the mould.

5. The method of claim 3 or 4, wherein at least part of the surface treatment is made by use of an embossing or stamping device (119”; 119’).

6. The method of any one of claims 3 - 5, wherein the surface treatment provides at least one letter, numeral, symbol and / or figure.

7. The method of any one of claims 1 - 6, wherein the powder premix (104) contains a filler agent (101), and a taste enhancer, an acidity regulator and sweetener agent(s) (102), and wherein in the product composition (113) of step c) the weight percentages contributed by the powder premix are: 10 -25% of the filler agent, 1 - 4 % of the taste enhancer, 0.01 - 2 % of the acidity regulator, and / or 0.2 - 2.1 % sweetener agent.

8. The method of any one of claims 1 - 7, wherein the powder premix contains micro crystalline cellulose powder (MCC) or chemical pulp powder as the filler agent (101), sodium chloride as the taste enhancer, sodium bicarbonate as the acidity regulator, and / or acesulfame K and / or xylitol as the sweetener agent.

9. The method of claim 7 or 8, wherein the powder premix further contains as additional powder ingredient (102) tobacco powder in the amount of 0.0001 - 0.9 % by weight of the product composition (113).

10. The method of any one of claims 1 - 9, wherein the total amount of water (105 and 110) supplied in steps a2) and blii) is 55 - 80 % by weight of the product composition (113) of step c).

11. The method of any one of claims 1 - 9, wherein in step bli) the amount liquid flavour(s) (108) are in the range of 0.6 - 6.5 % by weight of the product composition (113) of step c) .

12. The method of any one of claims 1 - 9, wherein in step bli) the amount of liquid active substance(s) is the range 0.1 - 4 % by weight of the product composition (113) of step c).

13. The method of any one of claims 1 - 12, wherein in step blii) the amount of binder agent (111) in powder phase is 1 - 5 % by weight of the product composition (115) of step c).

14. The method of claim 13, wherein the binder agent (111) in powder phase is one or more of: Agar, jelly, biopolymer and combinations of biopolymers.

15. The method of any one of claims 1 - 14, wherein plant fibers or starch fibers are added into the vessel (112) in step c) in the process of stirring to yield the product composition (113), and wherein the amount of the fibers is less than 10% by weight of the product composition (113).

16. The method of claim 15, wherein the plant fibers are non-tobacco fibers selected from one or more of natural untreated starches, bamboo fibers, softwood dissolving fibers, hardwood dissolving fibers, wheat fibers, rye fibers, oat fibers, barley fibers, flax fibers, hemp fibers, apple fibers, citrus fibers, and / or other fruit fibers.

17. The method of any one of claims 1 - 16, further added at least one non-tobacco water- soluble substance to the premix (104) in step al), and wherein the at least one substance is selectable from one or more of: vitamins, minerals, antioxidants, caffeine, terpenes, phytoncides, and amino acids.

18. The method of any one of claims 1 - 17, further added at least one non-nicotine material and stirred into the liquid amount in the mixer jar (109) in step bli).

19. The method of claim 18, wherein the at least one non-nicotine material is a mineral material selected from at least one of perlite, vermiculite, calcium phosphate, silicon dioxide and egg shells.

20. The method of any one of claims 1 -19, wherein the first set temperature (Tl) is in the range of either 35 - 70°C or 50 - 70°C.

21. The method of any one of claims 1 - 20, wherein the second temperature (T2) is in the range 40 - 50°C, preferably above 43°C, and wherein the third temperature (T3) is approximately 20°C.

22. A pouch-free oral product, wherein product ingredients by weight percentage are at least: 55-80 % of water, 10 - 25.9 % of filler material, 1 - 5 % of binder agent, 1 - 4 % of taste enhancer, 0.6 - 6.5 % of liquid flavour, 0.2 - 2.1 % of sweetener, 0.02 - 1 % of acidity regulator, and 0.1 - 4 % of liquid active substance.

23. The oral product of claim 22, wherein the filler material is at least a micro crystalline cellulose (MCC), wherein the binder agent is at least one of agar, jelly, biopolymer and a combination of biopolymers, and wherein the liquid active substance is nicotine and / or other active ingredient.

24. The oral product of claim 22, wherein the taste enhancer is sodium chloride, the liquid flavour is a single- or multi-component liquid, the sweetener is a single- or multi-component powder and the acidity regulator is sodium bicarbonate.

25. The oral product of claim 23, wherein the other active ingredient is selectable from one or more of: vitamins, minerals, antioxidants, caffeine, terpenes, phytoncides, and amino acids.

26. The oral product of claims 22 - 23, wherein the filler material further comprises tobacco powder in the amount of 0.001-0.9% by weight of the product composition (113).

27. A system for processing a pouch-free oral product as manufactured according to any one of the method claims 1 - 21, comprising: a controller station (120) to fill mould spaces (114’; 136) of a mould (114; 135) with a product composition (113) or product material matrix, a conveyor (125) or mould belt (135) to move the mould (114; 136) with product composition filled mould spaces (114’; 136) to a product surface treatment device (119; 119’; 119”), the surface treatment device exhibiting an embossing tool (129; 133) to make a pattern (117”; 117’”) on a face (117’) of the composition (113) present in a mould space (114’; 136),a cooling tunnel (116) downstream of the surface treatment device (119; 119’; 119”) to reduce the temperature of the product composition (113), and an exit (118) for discharging the moulded oral products (117) from the mould spaces (114’; 136) of the mould.

28. The system of claim 27, wherein the surface treatment device comprises a pusher device (127) and a stamp plate (128) with the embossing tool (129) on a lower surface of the stamp plate.

30. The system of claim 27, wherein the surface treatment device comprises a rotary roller (132) with the embossing tool (133) located around the circumference of the roller (132).

31. The system of claim 27, wherein the controller station (120) is configured to stop movement of the conveyor (125) when the mould (114) is aligned with the embossing tool (129) and until embossing on a face of the product material in the mould spaces (114’) is completed.

32. The system of claim 27, wherein a bottom face of the mould space (114’; 136) exhibits an embossing surface (114”; 136’) to create a matching embossed pattern on a face of the product composition (113) facing said embossing surface (114”; 136’).

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