Method for making rod-shaped smoking articles

Abstract

The method provides feeding a reconstituted filling material (R1) of plant origin along a first feed path. The filling material (R1) is obtained from a first continuous web (N1), obtained by the lamination and drying of a plant- based mixture (E). The method provides feeding a second continuous web (N2) of wrapping material along a second feed path which merges with the first feed path. The method then provides enfolding the filling material (R1) in the second continuous web (N2) so as to make continuous rod (B). Finally, the continuous rod (B) is cut to make a succession of rod-shaped smoking articles (A). The first continuous web (N1) is made by a lamination process for a mixture (E).

Description

[0001] DESCRIPTION

[0002] METHOD FOR MAKING ROD-SHAPED SMOKING ARTICLES.

[0003] Technical field

[0004] The present invention pertains to the field of smoking articles, and the object thereof is a method for making rod-shaped smoking articles.

[0005] Background art

[0006] In the pertinent field of the present invention, there are known apparatuses for making smoking articles which comprise a tubular wrapping made of paper material and an inner filling enfolded by the tubular wrapping and comprising a reconstituted material of plant origin.

[0007] An example of such a technology comprises a first feed line configured to feed a reconstituted first continuous web of plant origin along a first feed path and a second feed line configured to feed a second continuous web of paper material or the like along a second feed path converging with the first feed path. The apparatus further comprises a forming device configured to gather the first continuous web so as to make a continuous filling material being substantially cylindrical in shape. The apparatus then comprises a device configured to enfold the second continuous web around the continuous filling material so as to make a continuous rod. Finally, the apparatus comprises a cutting device configured to cut the continuous rod, obtaining a succession of rod-shaped smoking articles.

[0008] In particular, the first continuous web is made from a slurry type mixture, i.e., the first continuous web is obtained from the process called ‘casting’. Such a process provides making a mixture having a liquid consistency, obtained from a dry component comprising mainly ground tobacco, and a moist component comprising, for example, water, an aerosol generator, binding agents. The mixture thus obtained, which has a final moisture content of at least 70%, has a consistency suitable for being cast in the form of a layer onto a conveyor belt which conveys it into a drying device. The dried web is then processed to form the aforesaid filling material.

[0009] The Applicant has observed that such a technology, albeit operable, can be improved.

[0010] Firstly, it is worth noting how the use of slurry type mixtures requires increased drying times and increased drying energy costs due to the increased moisture content of the mixture itself.

[0011] Further, the use of the casting technology, associated with using a slurry mixture, requires implementing considerably large systems, which can be difficult to install in series with the machines for making smoking articles.

[0012] Therefore, it is the technical task of the present invention to provide a method for making smoking articles capable of overcoming the drawbacks which have emerged from the background art.

[0013] Disclosure of the invention

[0014] It is the object of the present invention to reduce time and costs for making the end product.

[0015] It is a further object of the invention to reduce the overall size requirements of the system, particularly in case of continuous web and continuous rod in-line production.

[0016] The specified technical task and the specified objects are substantially achieved by a method for making smoking articles comprising the technical features presented in appended claim 1 and / or in one or more of the claims dependent thereto.

[0017] Brief description of drawings

[0018] Further features and advantages of the present invention will become more apparent from the following indicative and thus non-limiting description of an embodiment of a method for making smoking articles according to the invention.

[0019] Such a description is presented below with reference to the accompanying drawings, provided by way of mere and thus non-limiting indication, in which:

[0020] - Figure 1 shows a diagrammatic view of a first embodiment of an apparatus for making rod-shaped smoking articles suitable for carrying out the method according to the invention;

[0021] - Figure 2 shows a diagrammatic view of a second embodiment of an apparatus for making smoking articles suitable for carrying out the method according to the invention;

[0022] - Figure 3 shows a sectional view of a preferred embodiment of the smoking article, made by means of the method according to the present invention.

[0023] Detailed description of preferred embodiments of the invention

[0024] According to the accompanying drawings, reference numeral ‘1 ’ globally indicates an apparatus (diagrammatically and only partially shown in the accompanying drawings) for making rod-shaped smoking articles, suitable for carrying out the method according to the invention. The expression ‘smoking articles’ means, within the scope of the present invention, both articles intended to achieve the combustion of a material (therefore, ‘conventional’ smoking articles) and articles intended to generate aerosol by means of heating a material (so-called ‘heat-not-burn’ articles) or parts thereof, i.e., single segments.

[0025] According to the present invention, the method provides firstly feeding a reconstituted filling material “R1” of plant origin along a first feed path. To this end, apparatus 1 comprises a first feed unit 2 configured to feed and move the reconstituted filling material “R1” of plant origin along the first feed path.

[0026] In the present description, the expression ‘material of plant origin’ means that the filling material “R1” mainly consists of substances originating from plants, in particular, having a leaf component.

[0027] According to an example, the reconstituted filling material “R1” of plant origin comprises a tobacco component and is preferably composed mainly of tobacco.

[0028] According to a further example, the reconstituted filling material “R1” of plant origin comprises a non-tobacco-based component, i.e., a material other than tobacco and preferably composed mainly of a non-tobacco base. According to such an example, the reconstituted filling material “R1” of plant origin can comprise a cellulose-based component and is preferably composed of cellulose. Alternatively, the reconstituted filling material “R1” of plant origin can comprise a component based on straw, rapeseed, hemp, cotton, or other plants suitable for making smoking articles. It is understood that the material of plant origin can comprise a tobacco component and a component other than tobacco.

[0029] Preferably, further, independently of the fact that the material of plant origin comprises or does not comprise tobacco, the reconstituted filling material “R1” of plant origin comprises at least one component for generating aerosol.

[0030] According to a further example, independently of the other components of the material of plant origin, the reconstituted filling material “R1” of plant origin comprises at least one flavoring additive.

[0031] The term ‘reconstituted’ means also that the filling material “R1” was made from grinding, shredding or fragmenting solid components. Such solid components are mixed with the liquid components so as to form a mixture | — „

[0032] According to a peculiar aspect of the present invention, independently of the specific composition of the material of plant origin, mixture “E” is processed by means of a lamination process so as to make a first continuous web “N1 ”. Then the first continuous web “N1” is processed so as to obtain the aforesaid reconstituted filling material “R1” of plant origin. In other words, the reconstituted filling material “R1” of plant origin is obtained from a first continuous web “N1” made by means of a lamination process for mixture “E”.

[0033] Specifically, mixture “E” is fed into a lamination unit 10 comprising one or more pairs of calibrated rollers 11 configured to shape the mixture “E” into a uniform layer, thus gradually reducing the thickness up to obtaining the desired thickness of the web. This compression and elongating process allows a thin web with a calibrated thickness to be obtained. Mixture “E” has a moisture content of less than 60% by weight, even more preferably less than 50% by weight.

[0034] According to the embodiment in Figure 1 , the lamination unit 10 is configured firstly to shape mixture “E” so as to obtain the first web “N1” and subsequently, to enfold the first web “N1” into a bobbin 12. Preferably, the winding into a bobbin is preceded by a drying stage in an oven (not shown). Subsequently, bobbin 12 of the first web “N1” is fed to the feed unit 2 (which can be placed at the same processing site as the lamination unit 10) and then introduced into the first feed path.

[0035] According to the embodiment in Figure 2, the lamination unit 10 is connected directly upstream to the feed unit 2, thus defining a single system. In other words, the lamination unit 10 is configured to shape mixture “E” so as to make the first web “N1”, and subsequently to feed the first web “N1” to the feed unit 2, preferably with the interposition of at least one drying stage (not shown).

[0036] Advantageously, employing a first continuous web “N1” of plant origin material obtained from a lamination process ensures the following advantages.

[0037] Firstly, the lamination is carried out on a mixture having a modest liquid content (generally, between 20% and 60% of the weight of the mixture), and this allows reducing the entity of the drying and, therefore, the sizes of the oven intended for the drying.

[0038] In general terms, the use of mixtures processable by lamination requires less drying time and reduced energy costs: with respect to slurry type mixtures, laminated mixtures tend to have a lower moisture content, reducing the drying time required and increasing the production process efficiency. Further, with lamination, it is possible to accurately control the thickness of the web produced, ensuring a high quality semi-finished product, which translates into a quality end product.

[0039] Simultaneously to feeding the first continuous web “N1 ”, the method provides feeding a second continuous web “N2” of wrapping material, preferably of paper material, along a second feed path converging with the first feed path. To this end, apparatus 1 comprises a second feed unit 3 configured to feed and move the second continuous web “N2” along the second feed path.

[0040] The method then provides obtaining a continuous rod “B” from the reconstituted filling material “R1” of plant origin, in which the reconstituted filling material “R1” of plant origin is in turn obtained from the first web “N1” made by means of the lamination process for mixture “E”. In other words, as will be more apparent in the continuation of the present description, the expression ‘obtaining a filling material’ indicates all those processing techniques known in the art capable of modifying the structure of the web so as to obtain a substantially cylindrical and consistent shape, ready to be used as core of the smoking segments or articles. To this end, apparatus 1 comprises a unit 4 for making the filling material, configured to obtain the filling material “R1” for a continuous rod “B”. For example, the continuous rod “B” is formed by means of the transverse gathering of the first continuous web “N1 ”, preferably by means of a convergent element. To facilitate such a gathering, the first continuous web “N1” can be subjected to crimping or cutting into parallel strips.

[0041] Subsequently, the method provides enfolding the continuous filling material “R1” by means of the second continuous web “N2” so as to make a continuous rod “B”, and transversely cutting such a continuous rod “B”, thus making a succession of rod-shaped smoking articles “A”. To this end, apparatus 1 comprises a shaping unit 5 for the continuous rod “B” and, downstream thereof, a cutting unit 6 for making the succession of rod-shaped smoking articles “A”. In particular, the shaping unit 5 of the continuous rod “B” can further comprise an applicator 7 for an adhesive substance onto the filling material “R1” or onto the second continuous web “N2”.

[0042] The rod-shaped smoking article “A” thus obtained therefore comprises a tubular wrapping “I” and an internal filling “R” enfolded by the tubular wrapping “I” and comprising a reconstituted material of plant origin, obtained from a first web of reconstituted material of plant origin, in particular, made by a lamination process for a mixture “E”.

[0043] A preferred embodiment of the article is shown, according to an enlarged cross-section view, in Figure 3.

[0044] According to an aspect of the present invention, prior to the step of obtaining the aforesaid filling material “R1” and independently of the presence of a crimping step, the method can provide a step of incising a side of the first continuous web “N1” to obtain, at least on such a side of the first continuous web “N1”, a plurality of longitudinal incisions according to a preset incising pattern (for example, by embossment).

[0045] According to an embodiment, at least one of the longitudinal incisions is made in continuous manner for the entire length of the first continuous web “N1”.

[0046] According to a further embodiment, at least one of the longitudinal incisions is made in discontinuous manner for the length of the first continuous web “N1 ”: each discontinuous longitudinal incision is defined by a succession of discrete incisions having a predetermined length. According to such an embodiment, at least one, preferably each of the longitudinal incisions extending in discontinuous manner along the surface of the first continuous web “N1” is a longitudinal incision passing through the entire thickness of the first continuous web “N1 ”.

[0047] According to an embodiment, the incision of the first continuous web “N1” is made according to a two-dimensional pattern.

[0048] To this ends, structurally, apparatus 1 can comprise a processing unit 8 for the first continuous web “N1”, arranged on the first feed path and configured to carry out the aforesaid crimping and / or the aforesaid incisions. Such a processing unit preferably comprises one or more pairs of rollers.

[0049] According to a further aspect of the invention, prior to the step of obtaining the aforesaid filling material “R1” and independently of the crimping and / or making of the aforesaid incisions, the method can provide a step of shredding the first continuous web “N1” into discrete segments. Such a step can be implemented after the step of longitudinally cutting the first continuous web “N1” into parallel strips so as to obtain a plurality of strip segments. Preferably, the discrete (strip) segments have an average length comprised between 10 and 50 mm and an average width comprised between 0.5 mm and 5 mm.

[0050] The longitudinal cuts and / or the fragmentation of the first continuous web “N1” can be carried out by means of the aforesaid processing unit of the first continuous web “N1 ”. In this case, the gathering step is carried out by means of a conveyor suitable for transporting the discrete segments and releasing the segments onto the second continuous web “N2”, in particular in the form of a continuous flow suitable for defining a continuous filling bead on the second continuous web “N2”.

Claims

CLAIMS1. A method for making rod-shaped smoking articles, comprising the following steps:- making a first continuous web (N1 ) by means of a lamination and drying process for a mixture (E) of plant origin;- processing said first continuous web (N1 ) to obtain a reconstituted filling material (R1 ) of plant origin;- feeding said filling material (R1 ) along a first feed path;- feeding a second continuous web (N2) of wrapping material along a second feed path which merges with the first feed path;- enfolding said filling material (R1 ) by means of said second continuous web (N2) so as to make a continuous rod (B);- cutting said continuous rod (B) transversely to make a succession of rodshaped smoking articles (A).

2. The method according to the preceding claim, wherein the step of processing the first continuous web (N1 ) comprises the sub-step of crimping the first continuous web (N1 ).

3. The method according to preceding claims 1 or 2, wherein the step of processing the first continuous web (N1 ) comprises the sub-step of incising at least one side of said first continuous web (N1 ) to make a plurality of longitudinal incisions according to a predetermined incising pattern.

4. The method according to the preceding claim, wherein at least one of said longitudinal incisions is made continuously along the full length of the first continuous web (N1 ), said continuous longitudinal incision not passing through the thickness of the first continuous web (N1 ).

5. The method according to claim 3 or 4, wherein at least one of said longitudinal incisions is discontinuously made along the length of the first continuous web (N1 ), wherein each discontinuous longitudinal incision is defined by a succession of discrete incisions of predetermined length, preferably passing longitudinally through the entire thickness of the firstcontinuous web (N1 ).

6. The method according to any one of the preceding claims, wherein the step of processing the first continuous web (N1 ) comprises the sub-step of longitudinally cutting the first continuous web (N1 ) so as to obtain a plurality of continuous strips.

7. The method according to any one of the preceding claims, wherein the step of processing the first continuous web (N1 ) comprises the sub-step of transversely gathering said first continuous web (N1 ), in particular by means of a converging element.

8. The method according to any one of the preceding claims, wherein the step of processing the first continuous web (N1 ) comprises the sub-step of shredding the first continuous web (N1 ) into discrete segments.

9. The method according to any one of the preceding claims, wherein said filling material (R1) comprises tobacco or is preferably composed mainly of tobacco.

10. The method according to any one of preceding claims 1 to 8, wherein the filling material (R1) comprises a material different from tobacco or is preferably composed mainly of a material different from tobacco.

11. The method according to claim 10, wherein said filling material (R1 ) comprises cellulose or is preferably composed mainly of cellulose.

12. The method according to any one of the preceding claims, wherein said step of feeding the filling material (R1 ) comprises a step of making a mixture (E), preferably with a moisture content of less than 60%, followed by a step of subjecting the mixture (E) to lamination, in particular by means of one or more pairs of calibrated rollers, to obtain said first continuous web (N1 ), preferably the first continuous web (N1 ) being subsequently subjected to drying.

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