Separating components of aerosol-generating articles with reduced cross-contamination

Abstract

There is disclosed a method of processing rod-shaped consumable aerosol-generating articles each comprising an aerosol-generating substrate portion including a metallic susceptor, the aerosol-generating generating substrate being longitudinally disposed between first end and second end plug portions, the aerosol-generating substrate and the first and second end plug portions being wrapped in at least one circumferential wrapper, the method comprising the steps of: i) feeding the aerosol-generating articles onto a vibrating sieve and causing the aerosol-generating articles to pass across a surface of the vibrating sieve; ii) arranging the aerosol-generating articles, after passage across the surface of the vibrating sieve, on an alignment belt comprising a plurality of transverse grooves configured to receive the aerosol-generating articles aligned substantially parallel to each other, the alignment belt having first and second opposed side edges; iii) positioning the aerosol-generating articles within the transverse grooves such that the first end plug portions abut at least one of the first and second opposed side edges of the alignment belt; iv) cutting the aerosol-generating articles at at least two points along a length of the aerosol-generating articles so as to separate the first end and second end plug portions from the aerosol-generating substrate portion; v) separating the aerosol-generating substrate portions from the first end plug portions and the second end plug portions; vi) separating the aerosol-generating substrate portions, including the metallic susceptors, from their circumferential wrappers; vii) cutting the aerosol-generating substrate portions so as to expose the metallic susceptors; viii) applying a magnetic field so as to separate the metallic susceptors from the aerosol-generating substrate portions; and ix) separately collecting the aerosol-generating substrate portions and the metallic susceptors.

Description

[0001] SEPARATING COMPONENTS OF AEROSOL-GENERATING ARTICLES WITH REDUCED CROSS-CONTAMINATION

[0002] The present disclosure relates to a method and system for separating components of aerosol-generating articles.

[0003] In the manufacture of aerosol-generating articles, for example heat-not-burn heated tobacco products, heat-not-burn nicotine-containing products, and hybrids thereof, various elements are combined to make the aerosol-generating articles. Typically, these articles comprise an aerosol-generating substrate, for example tobacco cast leaf, other agricultural products, such as clove, menthol and guar gum, glycerine, one or more filter elements, for example comprising a cellulosic material, an aerosol-cooling element, for example comprising a polylactic acid material or an acetate material, and a metallic susceptor element that, when heated, causes the aerosol-generating substrate to heat up and release an aerosol. The various elements are arranged in a desired configuration and assembled as rod-shaped articles wrapped in an outer wrapper, which may be made of paper or other material.

[0004] There are many different designs of aerosol-generating article, and the present disclosure is directed specifically at waste streams generated during the manufacture of aerosol-generating articles comprising both metal and non-metallic materials, or to waste streams comprising used aerosol-generating articles comprising both metal and non-metallic materials.

[0005] With reference to the manufacture of aerosol-generating articles, a production line may be set up to manufacture thousands or tens of thousands or even more aerosol-generating articles per hour. The aerosol-generating articles are subject to quality checks, and those that do not meet quality standards will be rejected and sent to a waste stream. The waste stream may comprise complete aerosol-generating articles that do not meet quality standards and partially complete aerosol-generating articles that have been rejected before completion. It would be desirable to separate the different components of the aerosol-generating articles in the waste stream for recycling and environmentally-responsible disposal.

[0006] It would also be desirable to separate components when processing used aerosolgenerating articles, which may have been collected from end users or testing machines.

[0007] Aerosol-generating articles in the form of consumable products for use with aerosolgenerating devices are known in the marketplace. Such aerosol-generating articles consist of multiple components arranged into a rod-like structure. Aerosol-generating articles designed for induction heating often incorporate an elongated metallic susceptor that is positioned longitudinally within an aerosol-generating substrate.

[0008] Moreover, such aerosol-generating articles often feature additional components such as filtering and air management segments, arranged in a sequential manner, often composed of cellulose-based materials. During the assembly process, the various components are first aligned in the desired order and then encased within an outer paper wrapper, which is applied tightly to maintain the integrity and shape of the article.

[0009] Figure 1 shows an aerosol-generating article 1 incorporating five distinct components arranged in coaxial alignment: a front plug 10, an aerosol-generating substrate rod 11 with a flat susceptor 12, a hollow acetate tube (HAT) filter 13, a fine hollow acetate tube (FHAT) filter 14, and a mouthpiece filter 15. These components are arranged sequentially and are tightly contained within an outer wrapper 16 and tipping paper 18 to form a cylindrical rod. The front plug 10 may be considered to be a first end plug portion, and the HAT filter 13, FHAT filter 14 and mouthpiece filter 15 may together be considered to be a second end plug portion. Alternatively, the HAT filter 13, FHAT filter 14 and mouthpiece filter 15 may together be considered to be a first end plug portion, and the front plug 10 may be considered to be a second end plug portion. The aerosol-generating substrate rod 11 , which may comprise leaf tobacco, ground tobacco, reconstituted cast-leaf tobacco, or other appropriate materials, is located between the first end plug portion and the second end plug portion.

[0010] Tables 1 and 2 below give examples of materials that may be used to form the various components and dimensions of the various components. The examples are illustrative, and are not to be taken as limiting unless the context requires otherwise.

[0011] Table 1 :

[0012] Table 2: When specifying the design of an aerosol-generating article, the dimensions are precisely defined. However, during the manufacturing and assembly processes of an aerosol-generating article, deviations in component dimensions and variations in the output of the assembly equipment may lead to discrepancies in the specifications of the finished product. In some instances, these variations can result in gaps 17 between the components. For example, when fully assembled, an aerosol-generating substrate rod 11 may not directly interface with adjacent components, but may be slightly displaced from its ideal position. The assembly equipment is typically configured continuously to monitor these process parameters and to take appropriate action depending on whether the aerosol-generating article is acceptable according to predefined tolerance targets. Furthermore, aerosol-generating articles may be rejected from the manufacturing process during initial packaging stages due to packaging deformities or rejected immediately after formation of the initial aerosol-generating substrate rod produced after crimping of the aerosol-generating substrate material.

[0013] Aerosol-generating articles failing to meet the necessary quality standards are considered defective and need to be removed before the final packaging stage of the final product. In order to minimize waste and maximize resources, it is common practice to recover the more valuable components from these rejected articles, for example the tobacco, to reintroduce it into the production process.

[0014] For the purpose of recovering tobacco substrate from defective smoking articles such as cigarettes, existing recovery systems known as "Reclaimers" are already in use. These systems typically involve crushing or ripping the articles and then sieving to recover the tobacco.

[0015] A significant drawback of the crushing-type or ripping-type reclaimers is the increased risk of cross-contamination during the disassembly process, particularly with articles that integrate multiple segments. This occurs when fragments from the outer wrapper or, if present, parts of the filter segments mix into the tobacco, leading to a decline in recovery efficiency.

[0016] More recent designs for recovery systems have attempted to solve the cross-contamination issue by incorporating cutting devices that provide a cleaner alternative to the crushing process. Instead, articles are conveyed towards a cutting blade that slices the different components of the article. After cutting, each individual component is transported for further recycling process.

[0017] While reclaimers equipped with cutting devices have demonstrated improved recovery yields compared to other types, they still encounter limitations when processing articles that incorporate metallic susceptors for induction heating. This is primarily due to their inability effectively to separate the susceptor from the aerosol-generating substrate.

[0018] Given the growing emphasis on meeting higher sustainability standards, current efforts in improving manufacturing practices are aimed at complying with these standards. Therefore, there remains a need to improve the recovery process to enhance sustainability and overall efficiency. According to a first aspect of the present invention, there is provided a method of processing rod-shaped consumable aerosol-generating articles each comprising an aerosol-generating substrate portion including a metallic susceptor, the aerosol-generating generating substrate being longitudinally disposed between first end and second end plug portions, the aerosolgenerating substrate and the first and second end plug portions being wrapped in at least one circumferential wrapper, the method comprising the steps of: i) feeding the aerosol-generating articles onto a vibrating sieve and causing the aerosol-generating articles to pass across a surface of the vibrating sieve; ii) arranging the aerosol-generating articles, after passage across the surface of the vibrating sieve, on an alignment belt comprising a plurality of transverse grooves configured to receive the aerosol-generating articles aligned substantially parallel to each other, the alignment belt having first and second opposed side edges; iii) positioning the aerosol-generating articles within the transverse grooves such that the first end plug portions abut at least one of the first and second opposed side edges of the alignment belt; iv) cutting the aerosol-generating articles at at least two points along a length of the aerosol-generating articles so as to separate the first end and second end plug portions from the aerosol-generating substrate portion; v) separating the aerosol-generating substrate portions from the first end plug portions and the second end plug portions; vi) separating the aerosol-generating substrate portions, including the metallic susceptors, from their circumferential wrappers; vii) cutting the aerosol-generating substrate portions so as to expose the metallic susceptors; viii) applying a magnetic field so as to separate the metallic susceptors from the aerosol-generating substrate portions; and ix) separately collecting the aerosol-generating substrate portions and the metallic susceptors.

[0019] The method of embodiments of the present invention provides a number of advantages over known processing methods. In particular, precision cutting of the aerosol-generating articles at at least two points along a length of each aerosol-generating article facilitates separation of the aerosol-generating substrate portion and included metallic susceptor from other components of the aerosol-generating articles. Additionally, the steps of cutting the aerosol-generating substrate portions to expose the metallic susceptors and applying a magnetic field to separate the metallic susceptors from the aerosol-generating substrate portions enables a particularly efficient separation of valuable aerosol-generating substrate, such as tobacco, from the metallic susceptors and other components. Moreover, the metallic susceptors can also be reused or recycled as appropriate.

[0020] Prior to step i), the aerosol-generating articles may be collected in a collecting hopper. The collecting hopper may be configured to operate as a buffer, in the sense that aerosolgenerating articles can be added to the collecting hopper batchwise in bulk, and the collecting hopper may be configured to dispense the aerosol-generating articles in a more controlled manner onto the vibrating sieve. For example, the collecting hopper may be configured to dispense the aerosol-generating articles one-by-one onto the vibrating sieve. For example, the collecting hopper may be configured to dispense the aerosol-generating articles in small batches, for example batches of two to twenty articles, or five to fifteen articles, at a time. For example, the collecting hopper may be configured to receive, at a top end, a large batch of tens or hundreds of aerosol-generating articles in one go, and to dispense, at a bottom end, aerosol-generating articles one-by-one or in small batches onto the vibrating sieve. In this way, a substantially continuous stream of singulated aerosol-generating articles can provided for passage across the vibrating sieve.

[0021] The aerosol-generating articles may be vibrated in the collecting hopper before being controllably fed to the vibrating sieve. The aerosol-generating articles may be vibrated in the collecting hopper by way of electromechanical shakers configured to vibrate a bulk of aerosol-generating articles in the collecting hopper. Aerosol-generating articles, especially when transported in bulk and tightly-packed, may become entangled with each other. Some of the aerosol-generating articles, which typically have a rod-shaped form factor, may become bent or curved, and become hooked on adjacent aerosol-generating articles. This can impede smooth flow of the aerosol-generating articles and lead to interruptions in the processing of the aerosol-generating articles. By vibrating the bulk of aerosol-generating articles in the collecting hopper, disentanglement of the aerosol-generating articles may be promoted, resulting in smoother flow with fewer process interruptions.

[0022] In step i), the aerosol-generating articles may be fed from the collecting hopper to the vibrating sieve by a vertical conveyor comprising shelf portions each configured to receive and transport a batch of aerosol-generating articles. A vertical conveyor may promote efficient utilization of available space within a processing facility. A vertical conveyer may have a smaller footprint than a corresponding horizontal conveyor.

[0023] In step i), the surface of the vibrating sieve may comprise a wire mesh or grid. In step i), the vibrating sieve may be vibrated at a frequency of 5Hz to 100Hz, optionally 30Hz to 60Hz. In step i), the vibrating sieve may be vibrated at a vibration amplitude of 1mm to 6mm, optionally 3mm to 4mm. The vibrating sieve may help to remove unwanted elements or contaminants from the stream of aerosol-generating articles, such as loose bits of paper or other detritus. The vibrating sieve may incorporate a mechanical or electromechanical shaker for providing controlled vibrations to the aerosol-generating articles. The controlled vibrations may be characterized by frequency or by amplitude or by frequency and amplitude to promote separation of the aerosol-generating articles from undesirable waste or foreign particles. Preferably, smaller waste or foreign particles fall through holes in the vibrating sieve, for example into a waste collection container, while the aerosol-generating articles traverse the surface of the vibrating sieve. The vibration frequency of the vibrating sieve may preferably be set to a relatively high value to promote rapid separation of the aerosolgenerating articles from each other. The amplitude of the vibrations of the vibrating sieve may be kept at a moderate value to reduce the likelihood of damaging the aerosol-generating articles. The direction of the vibrations, or the pattern of the vibrations, or the direction and pattern of the vibrations may be adjusted to promote substantially uniform distribution of the aerosol-generating articles across the surface of the vibrating sieve, thereby reducing unwanted clustering.

[0024] After step i) and prior to step ii), the aerosol-generating articles may be conveyed on an auxiliary belt comprising substantially parallel tracks running at different speeds so as to align the aerosol-generating articles longitudinally with a direction of travel. The substantially parallel running tracks may form individual longitudinal channels configured to receive the aerosol-generating articles aligned longitudinally with the direction of travel. The aerosolgenerating articles may be guided into the longitudinal channels by at least one brush. The at least one brush may be mounted on a motorized arm. The at least one brush may be mounted on a conveyor system. The at least one brush may have bristles that are designed gently to guide the aerosol-generating articles into the longitudinal channels. The at least one brush may help to ensure that the aerosol-generating articles are properly loaded into the longitudinal channels. The substantially parallel tracks running at different speeds act to align the aerosol-generating articles with each other and with the direction of travel. In this way, randomly-aligned aerosol generating articles from the vibrating sieve can be aligned with each other and with the direction of travel, which facilitates subsequent processing.

[0025] The aerosol-generating articles may be transferred from the auxiliary belt to a transfer hopper configured to collect the aerosol-generating articles substantially parallel to one another. The aerosol-generating articles may be aligned with one another in the transfer hopper.

[0026] A secondary belt, running substantially perpendicular to the auxiliary belt, may collect longitudinally-approaching aerosol-generating articles and convey the aerosol-generating articles to the transfer hopper where the aerosol-generating articles are temporarily held substantially parallel to one another before being dispensed onto the alignment belt in step ii). The transfer hopper may thus have both a buffering function and a dispensing function. In step ii), the transverse grooves of the alignment belt may have a length greater than a length of the aerosol-generating articles. This means that any given aerosol-generating article is slidable along the transverse groove of the alignment belt in which the aerosolgenerating article is located. The aerosol-generating article may be moved between one extreme position, in which the first end plug portion abuts one of the first and second opposed side edges, and another extreme position, in which the second end plug portion abuts the other of the first and second opposed side edges.

[0027] The alignment belt may include a sensor to determine an orientation of each aerosolgenerating article within its respective transverse groove. The sensor may determine whether the first end plug portion faces the first side edge or whether the first end plug portion faces the second side edge. The sensor may determine whether the second end plug portion faces the first side edge or whether the second end plug portion faces the second side edge. Generally, the aerosol-generating articles may take one of two possible orientations in the transverse grooves. In a first orientation the first end plug portion faces the first side edge and the second end plug portion faces the second side edge. In a second orientation the first end plug portion faces the second side edge and the second end plug portion faces the first side edge.

[0028] The aerosol-generating articles may be dispensed onto the alignment belt so as initially all to have one end abutting or adjacent to the first side edge of the alignment belt. As will be explained below, aerosol-generating articles in one orientation may be left in position abutting or adjacent to the first side edge of the alignment belt. Aerosol-generating articles in the other orientation may be moved along their transverse groove so as to abut or be adjacent to the second side edge of the alignment belt.

[0029] The sensor may be an optical sensor. The sensor may be an image sensor. The sensor may be a pattern recognition sensor configured to identify specific patterns on the at least one circumferential wrapper. The sensor may be configured to distinguish between the first and second end plug portions so as to determine the orientation of each aerosolgenerating article within its respective transverse groove. By executing image analysis and pattern recognition algorithms, the sensor may be able accurately to determine the orientation of each aerosol-generating article within its respective transverse groove by comparing a detected pattern against a library of stored reference patterns.

[0030] The sensor may determine whether the first end plug portion of a given aerosolgenerating article is closer than the second end plug portion to the first side edge of the alignment belt or whether the first end plug portion is closer than the second end plug portion to the second side edge of the alignment belt.

[0031] In step iii), the aerosol-generating articles may be moved within the transverse grooves, on the basis of the orientation determined by the sensor, so that the first end plug portions abut the respective first or second opposed side edges of the alignment belt. In this way, the aerosol-generating articles in the first orientation will be aligned with each other, all with their first end plug portions abutting one of the first and second opposed sides of the alignment belt, and the aerosol-generating articles in the second orientation will be aligned with each other, all with their first end plug portions abutting the other of the first and second opposed sides of the alignment belt. The aerosol-generating articles may be moved within the transverse grooves by an air jet. The aerosol-generating articles may be moved within the transverse grooves by an electromechanical actuator.

[0032] For example, if the sensor detects a first end plug portion, the sensor may send a signal to cause the aerosol-generating article to be moved within the transverse groove towards the first side of the alignment belt. If the sensor detects a second end plug portion, the sensor may send a signal to cause the aerosol-generating article to be moved within the transverse groove towards the second side of the alignment belt.

[0033] In step iv), each aerosol-generating article may be cut by a pair of rotating blades so as to separate the aerosol-generating substrate portion from the first end plug portion and the second end plug portion. Because the aerosol-generating articles are all aligned with those in the first orientation abutting the first side edge of the alignment belt and those in the second orientation abutting the second side edge of the alignment belt, the rotating blades will be correctly positioned even when the first end plug portion is of a different length than the second end plug portion. The rotating blades may be configured as circular or disc blades with a circumferential cutting edge.

[0034] A first pair of rotating blades may be provided adjacent to the first side of the alignment belt and a second pair of rotating blades may be provided adjacent to the second side of the alignment belt. This allows the aerosol-generating substrate portions of aerosol-generating articles abutting both sides of the alignment belt to be cut and separated from the first and second plug end portions.

[0035] The rotating blades may be spaced from each other along an axis of rotation by a distance corresponding to a length of the aerosol-generating substrate portion. The rotating blades may be spaced from each other by a distance corresponding to a length of the aerosol-generating substrate portion between the first end plug portion and the second end plug portion.

[0036] The alignment belt may be provided with recesses configured to receive cutting edges of the rotating blades so as to allow a complete cut-through of the aerosol-generating articles in the transverse grooves. The cutting edges of the rotating blades can thus extend through the alignment belt without damaging the alignment belt.

[0037] The rotating blades of each pair of rotating blades may be substantially parallel to each other. The rotating blades of each pair of rotating blades may share an axis of rotation.

[0038] The rotating blades may have toothed cutting edges. This may facilitate cutting of the aerosol-generating articles.

[0039] The rotating blades may have smooth cutting edges. This may reduce the amount of debris generated by the cutting process.

[0040] Each rotating blade may have a cutting width that is greater than a maximum spacing between the first plug end portion and the aerosol-generating substrate portion or greater than a maximum spacing between the second plug end portion and the aerosol-generating substrate portion. The maximum spacings may be determined according to manufacturing tolerances of the aerosol-generating articles. Account may be taken of imperfect abutting or alignment of the first end plug portions against the first or second side edges of the alignment belt. For example, a maximum possible gap between segments of an aerosol-generating article (e.g., a maximum possible gap between facing ends of the first end plug portion and the aerosol-generating substrate portion, or a maximum possible gap between facing ends of the second end plug portion and the aerosol-generating substrate portion) may be specified as 10 micrometres. A maximum possible deviation of an aerosol-generating article from its desired location within the respective transverse groove of the alignment belt may also be specified as 10 micrometres. In this case, each rotating blade may be specified with a cutting width of 20 micrometres. Other manufacturing tolerances may also be taken into account. This may help to reduce cross-contamination by ensuring that the cut aerosolgenerating substrate portion does not include any of the first end plug portion or the second end plug portion. This may help to reduce cross-contamination by ensuring that the cut first end plug portion does not include any of the aerosol-generating substrate portion. This may help to reduce cross-contamination by ensuring that the cut second end plug portion does not include any of the aerosol-generating substrate portion.

[0041] A mutual spacing of the rotating blades in each pair of rotating blades may be adjustable. The mutual spacing may be adjusted by a control unit in response to input parameters relating to a type of aerosol-generating article being processed. The mutual spacing is adjusted automatically in response to signals from a sensing unit that determines a length of each aerosol-generating substrate portion. The mutual spacing may be adjusted by a control unit in response to signals from a sensing that determines respective lengths of the first plug end portion, second plug end portion and aerosol-generating substrate portion. In this way, it is possible to process different type of aerosol-generating articles having different lengths of first plug end portion, second plug end portion or aerosol-generating substrate portion. A cutting angle of the rotating blades may be adjustable. The cutting angle may be adjusted by a control unit in response to input parameters relating to a type of aerosolgenerating article being processed.

[0042] In step iv), the aerosol-generating articles may be held in place in the transverse grooves during cutting. The aerosol-generating articles may be held in place in the transverse grooves by suction. The aerosol-generating articles may be held in place in the transverse grooves by a clamping roller. Holding the aerosol-generating articles in place during cutting may help to improve cutting accuracy. Holding the aerosol-generating articles in place during cutting may help to prevent the aerosol-generating articles from being dislodged from the transverse grooves by the rotating blades.

[0043] In step iv), debris from cutting the aerosol-generating articles may be extracted by at least one vacuum extractor. The at least one vacuum extractor may comprise an adjustable nozzle. Extracting cutting debris can help to reduce cross-contamination.

[0044] In step v), the first end plug portions, the second end plug portions and the aerosolgenerating substrate portions may be separated from one another. The first end plug portions may be displaced from the alignment belt to a first end plug portion collection receptacle. The second end plug portions may be displaced from the alignment belt to a second end plug portion collection receptacle. The first end plug portions or the second end plug portions may be displaced from the alignment belt by a pneumatic ejector. The first end plug portions or the second end plug portions or the first end plug portions and the second end plug portions may be taken away for recycling or subsequent processing or environmentally-responsible disposal.

[0045] In step vi), the aerosol-generating substrate portions, including the metallic susceptors, may be separated from their circumferential wrappers by a pneumatic ejector that applies an air jet to blow the aerosol-generating substrate portions, including the metallic susceptors, longitudinally out of their circumferential wrappers.

[0046] In step vi), the aerosol-generating substrate portions, including the metallic susceptors, may be separated from their circumferential wrappers by cutting the circumferential wrappers along a length of the aerosol-generating substrate portions.

[0047] In this way, it is possible to separate the aerosol-generating substrate portions, including the metallic susceptors, from their circumferential wrappers. The circumferential wrappers may be collected and taken away for recycling or subsequent processing or environmentally-responsible disposal.

[0048] In step vii), the aerosol-generating substrate portions may be cut along their lengths to expose the metallic susceptors. The aerosol-generating substrate portions may be cut along their lengths by a side-cutting knife. This may facilitate subsequent separation of the metallic susceptors from the aerosol-generating substrate portions. Between steps vii) and viii), the cut aerosol-generating substrate portions may be passed across a vibrating surface to promote disentanglement of the metallic susceptors from aerosol-generating substrate of the aerosol-generating substrate portions. The vibrating surface may comprise a sieve.

[0049] In step viii), aerosol-generating substrate of the aerosol-generating substrate portions and the metallic susceptors may be conveyed on a magnetic conveyor. The magnetic conveyor may comprise an endless driven belt with a magnetic roller at one end. The magnetic roller may retain the metallic susceptors on the endless belt as the endless belt passes around the magnetic roller while allowing the aerosol-generating substrate to fall into an aerosol-generating substrate collection receptacle. The metallic susceptors may fall from an underside of the endless belt as the metallic susceptors are conveyed away from the magnetic roller. The metallic susceptors may fall from the underside of the endless belt into a metallic susceptor collection receptacle. This can promote separation of the metallic susceptors from non-magnetic pieces of aerosol-generating substrate. The magnetic roller may comprise at least one electromagnet. The magnetic roller may comprise at least one permanent magnet.

[0050] In step viii), aerosol-generating substrate of the aerosol-generating substrate portions and the metallic susceptors may be conveyed on a first conveyor, and the magnetic field may be applied by an over-band magnetic conveyor that passes over the first conveyor. The over-band magnetic conveyor may comprise a magnet that is disposed over the first conveyor so as to cause the metallic susceptors to lift away from the first conveyor and to be conveyed away from the first conveyor on an underside of the over-band magnetic conveyor. The over-band magnetic conveyor may convey the metallic susceptors to a metallic susceptor collection receptacle. The over-band conveyor may comprise an electromagnet. The over-band conveyor may comprise a permanent magnet. In this way, the metallic susceptors may be effectively separated from non-magnetic pieces of aerosol-generating substrate.

[0051] Both the metallic susceptors and the aerosol-generating substrate are valuable commodities, and once separated from each other can be sent for subsequent processing or recycling.

[0052] According to a second aspect of the present invention, there is provided a system for processing rod-shaped consumable aerosol-generating articles each comprising an aerosolgenerating substrate portion including a metallic susceptor, the aerosol-generating generating substrate being longitudinally disposed between first end and second end plug portions, the aerosol-generating substrate and the first and second end plug portions being wrapped in at least one circumferential wrapper, the system comprising: i) a vibrating sieve configured to receive the aerosol-generating articles, the vibrating sieve having a surface across which the aerosol-generating articles are passed; ii) an alignment belt comprising a plurality of transverse grooves configured to receive the aerosol-generating articles aligned substantially parallel to each other, the alignment belt having first and second opposed side edges; iii) actuators configured to position the aerosol-generating articles within the transverse grooves such that the first end plug portions abut at least one of the first and second opposed side edges of the alignment belt; iv) cutters configured to cut the aerosol-generating articles at at least two points along a length of the aerosol-generating articles so as to separate the first end and second end plug portions from the aerosol-generating substrate portion; v) a first separator configured to separate the aerosol-generating substrate portions from the first end plug portions and the second end plug portions; vi) a second separator configured to separate the aerosol-generating substrate portions, including the metallic susceptors, from their circumferential wrappers; vii) a cutter configured to cut the aerosol-generating substrate portions so as to expose the metallic susceptors; and viii) a magnet configured to apply a magnetic field so as to separate the metallic susceptors from the aerosol-generating substrate portions.

[0053] The system may further comprise a collecting hopper configured to collect the aerosolgenerating articles prior to passage across the surface of the vibrating sieve. The collecting hopper may be configured to vibrate the aerosol-generating articles and controllably to feed the aerosol-generating articles to the vibrating sieve.

[0054] The system may further comprise a vertical conveyor having shelf portions each configured to receive and transport a batch of aerosol-generating articles, the vertical conveyor configured to feed the aerosol-generating articles from the collecting hopper to the vibrating sieve.

[0055] The surface of the vibrating sieve may comprise a wire mesh or grid.

[0056] The vibrating sieve may be provided with a vibrator configured to vibrate the surface at a frequency of 5Hz to 100Hz, optionally 30Hz to 60Hz.

[0057] The vibrating sieve may be provided with a vibrator configured to vibrate the surface at a vibration amplitude of 1 mm to 6mm, optionally 3mm to 4mm.

[0058] The system may further comprise an auxiliary belt having substantially parallel tracks running at different speeds so as to align the aerosol-generating articles longitudinally with a direction of travel. The substantially parallel running tracks may form individual longitudinal channels configured to receive the aerosol-generating articles aligned longitudinally with the direction of travel. The system may further comprise at least one brush configured to guide the aerosol-generating articles into the longitudinal channels.

[0059] The system may further comprise a transfer hopper configured to receive the aerosolgenerating articles from the auxiliary belt and to collect the aerosol-generating articles substantially parallel to one another. The system may further comprise a secondary belt, running substantially perpendicular to the auxiliary belt, configured to collect longitudinally- approaching aerosol-generating articles and to convey the aerosol-generating articles to the transfer hopper where the aerosol-generating articles are temporarily held substantially parallel to one another before being dispensed onto the alignment belt.

[0060] The transverse grooves of the alignment belt may have a length greater than a length of the aerosol-generating articles. The system may further comprise a sensor configured to determine an orientation of each aerosol-generating article within its respective transverse groove. The sensor may be an optical sensor. The sensor may be an image sensor. The sensor may be a pattern recognition sensor configured to identify specific patterns on the at least one circumferential wrapper. The sensor may be configured to determine whether the first end plug portion of a given aerosol-generating article is closer than the second end plug portion to the first side edge of the alignment belt or whether the first end plug portion is closer than the second end plug portion to the second side edge of the alignment belt.

[0061] The system may further comprise an air jet configured to move the aerosol-generating articles within the transverse grooves, on the basis of the orientation determined by the sensor, so that the first end plug portions abut the respective first or second opposed side edges of the alignment belt.

[0062] The system may further comprise an electromechanical actuator configured to move the aerosol-generating articles within the transverse grooves, on the basis of the orientation determined by the sensor, so that the first end plug portions abut the respective first or second opposed side edges of the alignment belt.

[0063] The cutters configured to cut the aerosol-generating articles at at least two points along a length of the aerosol-generating articles may comprise a pair of rotating blades configured to separate the aerosol-generating substrate portion from the first end plug portion and the second end plug portion. A first pair of rotating blades may be provided adjacent to the first side of the alignment belt and a second pair of rotating blades may be provided adjacent to the second side of the alignment belt.

[0064] The rotating blades may be spaced from each other along an axis of rotation by a distance corresponding to a length of the aerosol-generating substrate portion.

[0065] The alignment belt may be provided with recesses configured to receive cutting edges of the rotating blades so as to allow a complete cut-through of the aerosol-generating articles in the transverse grooves. The rotating blades of each pair of rotating blades may be substantially parallel to each other. The rotating blades of each pair of rotating blades may share an axis of rotation.

[0066] The rotating blades may have toothed cutting edges. The rotating blades may have smooth cutting edges.

[0067] Each rotating blade may have a cutting width that is greater than a maximum spacing between the first plug end portion and the aerosol-generating substrate portion or greater than a maximum spacing between the second plug end portion and the aerosol-generating substrate portion.

[0068] A mutual spacing of the rotating blades in each pair of rotating blades may be adjustable. The system may further comprise a control unit configured to adjust the mutual spacing in response to input parameters relating to a type of aerosol-generating article being processed. The system may further comprise a sensing unit configured to determine a length of each aerosol-generating substrate portion and a control unit configured to adjust the mutual spacing in response the determined length of each aerosol-generating substrate portion.

[0069] A cutting angle of the rotating blades may be adjustable. The system may further comprise a control unit configured to adjust a cutting angle of the rotating blades in response to input parameters relating to a type of aerosol-generating article being processed.

[0070] The alignment belt may be configured to hold the aerosol-generating articles in place in the transverse grooves during cutting. The transverse grooves in the alignment belt may be provided with suction holes to hold the aerosol-generating articles in place in the transverse grooves during cutting. The system may further comprise a clamping roller to hold the aerosol-generating articles in place in the transverse grooves during cutting.

[0071] The system may further comprise at least one vacuum extractor configured to extract debris from cutting the aerosol-generating articles. The at least one vacuum extractor may comprise an adjustable nozzle.

[0072] The first separator may be configured to separate the first end plug portions, the second end plug portions and the aerosol-generating substrate portions from one another. The alignment belt may be configured to displace the first end plug portions from the alignment belt to a first end plug portion collection receptacle. The alignment belt may be configured to displace the second end plug portions from the alignment belt to a second end plug portion collection receptacle. The first separator may comprise a pneumatic ejector configured to displace the first end plug portions or the second end plug portions from the alignment belt.

[0073] The second separator may comprise a pneumatic ejector configured to apply an air jet to blow the aerosol-generating substrate portions, including the metallic susceptors, longitudinally out of their circumferential wrappers. The second separator may comprise a cutter configured to cut the circumferential wrappers along a length of the aerosol-generating substrate portions.

[0074] The cutter of item vii) may be configured to cut the aerosol-generating substrate portions along their lengths to expose the metallic susceptors. The cutter of item vii) may be a side-cutting knife.

[0075] The system may further comprise, between items vii) and viii), a vibrating surface configured to promote disentanglement of the metallic susceptors from aerosol-generating substrate of the aerosol-generating substrate portions. The vibrating surface may comprise a sieve.

[0076] The magnet may be incorporated in a magnetic conveyor configured to convey aerosolgenerating substrate of the aerosol-generating substrate portions and the metallic susceptors. The magnetic conveyor may comprise an endless driven belt with a magnetic roller at one end. The magnetic roller may be configured to retain the metallic susceptors on the endless belt as the endless belt passes around the magnetic roller while allowing the aerosol-generating substrate to fall into an aerosol-generating substrate collection receptacle. The magnetic roller and the endless belt may be configured to cause the metallic susceptors to fall from an underside of the endless belt as the metallic susceptors are conveyed away from the magnetic roller. The system may further comprise a metallic susceptor collection receptacle into which the metallic susceptors fall from the underside of the endless belt. The magnetic roller may comprise at least one electromagnet. The magnetic roller may comprise at least one permanent magnet.

[0077] Aerosol-generating substrate of the aerosol-generating substrate portions and the metallic susceptors may be conveyed on a first conveyor, and the magnet may be incorporated in an over-band magnetic conveyor that passes over the first conveyor. The magnet of the over-band magnetic conveyor may be disposed over the first conveyor so as to cause the metallic susceptors to lift away from the first conveyor and to be conveyed away from the first conveyor on an underside of the over-band magnetic conveyor. The over-band magnetic conveyor may be configured to convey the metallic susceptors to a metallic susceptor collection receptacle. The magnet of the over-band conveyor may comprise an electromagnet. The magnet of the over-band conveyor may comprise a permanent magnet.

[0078] Advantages of the various optional features described in relation to the first aspect of the present invention apply equally to the respective optional features of the second aspect of the present invention.

[0079] In the context of the present disclosure, the term “aerosol-generating article” is intended to mean an article comprising an aerosol-generating substrate that is configured to be used with an aerosol-generating device. The aerosol-generating substrate may comprise a nicotine-containing substance, e.g. tobacco. The article may comprise additional components such as a mouthpiece, an aerosol mixing portion, a filter portion, a flavour portion and so forth. An aerosol-generating article preferably has a rod-like or cylindrical form factor. An aerosol-generating article preferably has a constant cross-section along its length, which may be circular, elliptical or oval, but could also have other shapes, including polygonal.

[0080] In the context of the present disclosure, the term “aerosol-generating substrate” is intended to mean a substrate that is capable of generating an aerosol when heated. Examples of aerosolgenerating substrates include tobacco cast leaf formed from a slurry of ground tobacco leaves and suitable binders, and also mixtures of nicotine with one or more of glycerine, guar gum, menthol, cloves, other flavourings, other agricultural products, or high retention material with nicotine content.

[0081] In the context of the present disclosure, the term “belt” is intended to mean an endless conveyor that passes over at least two rollers and is configured to transport aerosol-generating articles in a desired direction, preferably in a desired orientation.

[0082] In the context of the present disclosure, the terms “first end plug portion” and “second end plug portion” are intended, respectively, to mean first and second longitudinally opposed ends of an aerosol-generating article, each comprising a filter-type element configured to allow passage of air through the aerosol-generating article. The aerosol-generating substrate is disposed between the first and second end plug portions in the aerosol-generating article.

[0083] In the context of the present disclosure, the term “metallic susceptor” is intended to mean a substantially laminar metal element, for example in the form of a metal foil, that is disposed in or adjacent to an aerosol-generating substrate, and which can be heated by resistive or inductive heating so as to cause the aerosol-generating substrate to generate an aerosol.

[0084] In the context of the present disclosure, the terms “upstream” and “downstream” are used to describe the relative positions of components of the apparatus or steps of the method with reference to a direction of travel of the web of crimped material.

[0085] In the context of the present disclosure, the term “vibrating sieve” is intended to mean a machinery component that comprises a perforated or mesh surface that is able to be vibrated at a desired frequency and amplitude of vibration. The vibration may be substantially perpendicular to a plane of the surface. In some variants, the vibration may alternatively or additionally be in another plane, for example parallel to a plane of the surface, or at an angle other than 90 degrees to the plane of the surface. The vibrating sieve may be vibrated by way of a motor or by other appropriate mechanisms. The vibrating sieve may be provided with raised side edges to help direct the stream from one end of the surface to the other end of the surface. Small bits of debris or other contaminants will fall through holes in the perforated or mesh surface and can be collected for disposal. The invention is defined in the claims. However, below there is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

[0086] Example Ex1 : A method of processing rod-shaped consumable aerosol-generating articles each comprising an aerosol-generating substrate portion including a metallic susceptor, the aerosol-generating generating substrate being longitudinally disposed between first end and second end plug portions, the aerosol-generating substrate and the first and second end plug portions being wrapped in at least one circumferential wrapper, the method comprising the steps of: i) feeding the aerosol-generating articles onto a vibrating sieve and causing the aerosol-generating articles to pass across a surface of the vibrating sieve; ii) arranging the aerosol-generating articles, after passage across the surface of the vibrating sieve, on an alignment belt comprising a plurality of transverse grooves configured to receive the aerosol-generating articles aligned substantially parallel to each other, the alignment belt having first and second opposed side edges; iii) positioning the aerosol-generating articles within the transverse grooves such that the first end plug portions abut at least one of the first and second opposed side edges of the alignment belt; iv) cutting the aerosol-generating articles at at least two points along a length of the aerosol-generating articles so as to separate the first end and second end plug portions from the aerosol-generating substrate portion; v) separating the aerosol-generating substrate portions from the first end plug portions and the second end plug portions; vi) separating the aerosol-generating substrate portions, including the metallic susceptors, from their circumferential wrappers; vii) cutting the aerosol-generating substrate portions so as to expose the metallic susceptors; viii) applying a magnetic field so as to separate the metallic susceptors from the aerosol-generating substrate portions; and ix) separately collecting the aerosol-generating substrate portions and the metallic susceptors.

[0087] Example Ex2: The method of Example Ex1 , wherein prior to step i), the aerosolgenerating articles are collected in a collecting hopper.

[0088] Example Ex3: The method of Example Ex2, wherein the aerosol-generating articles are vibrated in the collecting hopper before being controllably fed to the vibrating sieve.

[0089] Example Ex4: The method of Example Ex2 or Ex3, wherein in step i), the aerosolgenerating articles are fed from the collecting hopper to the vibrating sieve by a vertical conveyor comprising shelf portions each configured to receive and transport a batch of aerosol-generating articles.

[0090] Example Ex5: The method of any one of Examples Ex1 to Ex4, wherein in step i), the surface of the vibrating sieve comprises a wire mesh or grid.

[0091] Example Ex6: The method of any one of Examples Ex1 to Ex5, wherein in step i), the vibrating sieve is vibrated at a frequency of 5Hz to 100Hz, optionally 30Hz to 60Hz.

[0092] Example Ex7: The method of any one of Examples Ex1 to Ex6, wherein in step i), the vibrating sieve is vibrated at a vibration amplitude of 1 mm to 6mm, optionally 3mm to 4mm.

[0093] Example Ex8: The method of any one of Examples Ex1 to Ex7, wherein after step i) and prior to step ii), the aerosol-generating articles are conveyed on an auxiliary belt comprising substantially parallel tracks running at different speeds so as to align the aerosol-generating articles longitudinally with a direction of travel.

[0094] Example Ex9: The method of Example Ex8, wherein the substantially parallel running tracks form individual longitudinal channels configured to receive the aerosol-generating articles aligned longitudinally with the direction of travel.

[0095] Example Ex10: The method of Example Ex9, wherein the aerosol-generating articles are guided into the longitudinal channels by at least one brush.

[0096] Example Ex11 : The method of any one of Examples Ex8 to Ex10, wherein the aerosolgenerating articles are transferred from the auxiliary belt to a transfer hopper configured to collect the aerosol-generating articles substantially parallel to one another.

[0097] Example Ex12: The method of Example Ex11 , wherein a secondary belt, running substantially perpendicular to the auxiliary belt, collects longitudinally-approaching aerosolgenerating articles and conveys the aerosol-generating articles to the transfer hopper where the aerosol-generating articles are temporarily held substantially parallel to one another before being dispensed onto the alignment belt in step ii).

[0098] Example Ex13: The method of any one of Examples Ex1 to Ex12, wherein in step ii), the transverse grooves of the alignment belt have a length greater than a length of the aerosolgenerating articles.

[0099] Example Ex14: The method of Example Ex13, wherein the alignment belt includes a sensor to determine an orientation of each aerosol-generating article within its respective transverse groove.

[0100] Example Ex15: The method of Example Ex14, wherein the sensor is an optical sensor.

[0101] Example Ex16: The method of Example Ex14 or Ex15, wherein the sensor is an image sensor.

[0102] Example Ex17: The method of any one of Examples Ex14 to Ex16, wherein the sensor is a pattern recognition sensor configured to identify specific patterns on the at least one circumferential wrapper. Example Ex18: The method of any one of Examples Ex14 to Ex17, wherein the sensor determines whether the first end plug portion of a given aerosol-generating article is closer than the second end plug portion to the first side edge of the alignment belt or whether the first end plug portion is closer than the second end plug portion to the second side edge of the alignment belt.

[0103] Example Ex19: The method of Example Ex18, wherein in step iii), the aerosolgenerating articles are moved within the transverse grooves, on the basis of the orientation determined by the sensor, so that the first end plug portions abut the respective first or second opposed side edges of the alignment belt.

[0104] Example Ex20: The method of Example Ex19, wherein the aerosol-generating articles are moved within the transverse grooves by an air jet.

[0105] Example Ex21 : The method of Example Ex19, wherein the aerosol-generating articles are moved within the transverse grooves by an electromechanical actuator.

[0106] Example Ex22: The method of any one of Examples Ex1 to Ex21 , wherein in step iv), each aerosol-generating article is cut by a pair of rotating blades so as to separate the aerosol-generating substrate portion from the first end plug portion and the second end plug portion.

[0107] Example Ex23: The method of Example Ex22, wherein a first pair of rotating blades is provided adjacent to the first side of the alignment belt and a second pair of rotating blades is provided adjacent to the second side of the alignment belt.

[0108] Example Ex24: The method of Example Ex22 or Ex23, wherein the rotating blades are spaced from each other along an axis of rotation by a distance corresponding to a length of the aerosol-generating substrate portion.

[0109] Example Ex25: The method of any one of Examples Ex22 to Ex24, wherein the alignment belt is provided with recesses configured to receive cutting edges of the rotating blades so as to allow a complete cut-through of the aerosol-generating articles in the transverse grooves.

[0110] Example Ex26: The method of any one of Examples Ex22 to Ex25, wherein the rotating blades of each pair of rotating blades are substantially parallel to each other.

[0111] Example Ex27: The method of any one of Examples Ex22 to Ex26, wherein the rotating blades of each pair of rotating blades share an axis of rotation.

[0112] Example Ex28: The method of any one of Examples Ex22 to Ex27, wherein the rotating blades have toothed cutting edges.

[0113] Example Ex29: The method of any one of Examples Ex22 to Ex27, wherein the rotating blades have smooth cutting edges.

[0114] Example Ex30: The method of any one of Examples Ex22 to Ex29, wherein each rotating blade has a cutting width that is greater than a maximum spacing between the first plug end portion and the aerosol-generating substrate portion or greater than a maximum spacing between the second plug end portion and the aerosol-generating substrate portion.

[0115] Example Ex31 : The method of any one of Examples Ex22 to Ex30, wherein a mutual spacing of the rotating blades in each pair of rotating blades is adjustable.

[0116] Example Ex32: The method of Example Ex31 , wherein the mutual spacing is adjusted by a control unit in response to input parameters relating to a type of aerosol-generating article being processed.

[0117] Example Ex33: The method of Example Ex31 , wherein the mutual spacing is adjusted automatically in response to signals from a sensing unit that determines a length of each aerosol-generating substrate portion.

[0118] Example Ex34: The method of any one of Examples Ex22 to Ex33, wherein a cutting angle of the rotating blades is adjustable.

[0119] Example Ex35: The method of Example Ex34, wherein the cutting angle is adjusted by a control unit in response to input parameters relating to a type of aerosol-generating article being processed.

[0120] Example Ex36: The method of any one of Examples Ex1 to Ex35, wherein in step iv), the aerosol-generating articles are held in place in the transverse grooves during cutting.

[0121] Example Ex37: The method of Example Ex36, wherein the aerosol-generating articles are held in place in the transverse grooves by suction.

[0122] Example Ex38: The method of Example Ex36, wherein the aerosol-generating articles are held in place in the transverse grooves by a clamping roller.

[0123] Example Ex39: The method of any one of Examples Ex1 to Ex38, wherein in step iv), debris from cutting the aerosol-generating articles is extracted by at least one vacuum extractor.

[0124] Example Ex40: The method of Example Ex39, wherein the at least one vacuum extractor comprises an adjustable nozzle.

[0125] Example Ex41 : The method of any one of Examples Ex1 to Ex39, wherein in step v), the first end plug portions, the second end plug portions and the aerosol-generating substrate portions are separated from one another.

[0126] Example Ex42: The method of Example Ex41 , wherein the first end plug portions are displaced from the alignment belt to a first end plug portion collection receptacle.

[0127] Example Ex43: The method of Example Ex41 or Ex42, wherein the second end plug portions are displaced from the alignment belt to a second end plug portion collection receptacle.

[0128] Example Ex44: The method of any one of Examples Ex41 to Ex43, wherein the first end plug portions or the second end plug portions are displaced from the alignment belt by a pneumatic ejector. Example Ex45: The method of any one of Examples Ex1 to Ex44, wherein in step vi), the aerosol-generating substrate portions, including the metallic susceptors, are separated from their circumferential wrappers by a pneumatic ejector that applies an air jet to blow the aerosol-generating substrate portions, including the metallic susceptors, longitudinally out of their circumferential wrappers.

[0129] Example Ex46: The method of any one of Examples Ex1 to Ex44, wherein in step vi), the aerosol-generating substrate portions, including the metallic susceptors, are separated from their circumferential wrappers by cutting the circumferential wrappers along a length of the aerosol-generating substrate portions.

[0130] Example Ex47: The method of any one of Examples Ex1 to Ex46, wherein in step vii), the aerosol-generating substrate portions are cut along their lengths to expose the metallic susceptors.

[0131] Example Ex48: The method of Example Ex47, wherein the aerosol-generating substrate portions are cut along their lengths by a side-cutting knife.

[0132] Example Ex49: The method of any one of Examples Ex1 to Ex48, wherein between steps vii) and viii), the cut aerosol-generating substrate portions are passed across a vibrating surface to promote disentanglement of the metallic susceptors from aerosolgenerating substrate of the aerosol-generating substrate portions.

[0133] Example Ex50: The method of Example Ex49, wherein the vibrating surface comprises a sieve.

[0134] Example Ex51 : The method of any one of Examples Ex1 to Ex50, wherein in step viii), aerosol-generating substrate of the aerosol-generating substrate portions and the metallic susceptors are conveyed on a magnetic conveyor.

[0135] Example Ex52: The method of Example Ex51 , wherein the magnetic conveyor comprises an endless driven belt with a magnetic roller at one end.

[0136] Example Ex53: The method of Example Ex52, wherein the magnetic roller retains the metallic susceptors on the endless belt as the endless belt passes around the magnetic roller while allowing the aerosol-generating substrate to fall into an aerosol-generating substrate collection receptacle.

[0137] Example Ex54: The method of Example Ex53, wherein the metallic susceptors fall from an underside of the endless belt as the metallic susceptors are conveyed away from the magnetic roller.

[0138] Example Ex55: The method of Example Ex54, wherein the metallic susceptors fall from the underside of the endless belt into a metallic susceptor collection receptacle.

[0139] Example Ex56: The method of any one of Examples Ex52 to Ex55, wherein the magnetic roller comprises at least one electromagnet. Example Ex57: The method of any one of Examples Ex52 to Ex55, wherein the magnetic roller comprises at least one permanent magnet.

[0140] Example Ex58: The method of any one of Examples Ex1 to Ex50, wherein in step viii), aerosol-generating substrate of the aerosol-generating substrate portions and the metallic susceptors are conveyed on a first conveyor, and wherein the magnetic field is applied by an over-band magnetic conveyor that passes over the first conveyor.

[0141] Example Ex59: The method of Example Ex58, wherein the over-band magnetic conveyor comprises a magnet that is disposed over the first conveyor so as to cause the metallic susceptors to lift away from the first conveyor and to be conveyed away from the first conveyor on an underside of the over-band magnetic conveyor.

[0142] Example Ex60: The method of Example Ex58 or Ex59, wherein the over-band magnetic conveyor conveys the metallic susceptors to a metallic susceptor collection receptacle.

[0143] Example Ex61 : The method of any one of Examples Ex58 to Ex60, wherein the overband conveyor comprises an electromagnet.

[0144] Example Ex62: The method of any one of Examples Ex58 to Ex60, wherein the overband conveyor comprises a permanent magnet.

[0145] Example Ex63: A system for processing rod-shaped consumable aerosol-generating articles each comprising an aerosol-generating substrate portion including a metallic susceptor, the aerosol-generating generating substrate being longitudinally disposed between first end and second end plug portions, the aerosol-generating substrate and the first and second end plug portions being wrapped in at least one circumferential wrapper, the system comprising: i) a vibrating sieve configured to receive the aerosol-generating articles, the vibrating sieve having a surface across which the aerosol-generating articles are passed; ii) an alignment belt comprising a plurality of transverse grooves configured to receive the aerosol-generating articles aligned substantially parallel to each other, the alignment belt having first and second opposed side edges; iii) actuators configured to position the aerosol-generating articles within the transverse grooves such that the first end plug portions abut at least one of the first and second opposed side edges of the alignment belt; iv) cutters configured to cut the aerosol-generating articles at at least two points along a length of the aerosol-generating articles so as to separate the first end and second end plug portions from the aerosol-generating substrate portion; v) a first separator configured to separate the aerosol-generating substrate portions from the first end plug portions and the second end plug portions; vi) a second separator configured to separate the aerosol-generating substrate portions, including the metallic susceptors, from their circumferential wrappers; vii) a cutter configured to cut the aerosol-generating substrate portions so as to expose the metallic susceptors; and viii) a magnet configured to apply a magnetic field so as to separate the metallic susceptors from the aerosol-generating substrate portions.

[0146] Example Ex64: The system of Example Ex63, further comprising a collecting hopper configured to collect the aerosol-generating articles prior to passage across the surface of the vibrating sieve.

[0147] Example Ex65: The system of Example Ex64, wherein the collecting hopper is configured to vibrate the aerosol-generating articles and controllably to feed the aerosolgenerating articles to the vibrating sieve.

[0148] Example Ex66: The system of Example Ex64 or Ex65, further comprising a vertical conveyor having shelf portions each configured to receive and transport a batch of aerosolgenerating articles, the vertical conveyor configured to feed the aerosol-generating articles from the collecting hopper to the vibrating sieve.

[0149] Example Ex67: The system of any one of Examples Ex63 to Ex66, wherein the surface of the vibrating sieve comprises a wire mesh or grid.

[0150] Example Ex68: The system of any one of Examples Ex63 to Ex67, wherein the vibrating sieve is provided with a vibrator configured to vibrate the surface at a frequency of 5Hz to 100Hz, optionally 30Hz to 60Hz.

[0151] Example Ex69: The system of any one of Examples Ex63 to Ex68, wherein the vibrating sieve is provided with a vibrator configured to vibrate the surface at a vibration amplitude of 1 mm to 6mm, optionally 3mm to 4mm.

[0152] Example Ex70: The system of any one of Examples Ex63 to Ex69, further comprising an auxiliary belt having substantially parallel tracks running at different speeds so as to align the aerosol-generating articles longitudinally with a direction of travel.

[0153] Example Ex71 : The system of Example Ex70, wherein the substantially parallel running tracks form individual longitudinal channels configured to receive the aerosol-generating articles aligned longitudinally with the direction of travel.

[0154] Example Ex72: The system of Example Ex71 , further comprising at least one brush configured to guide the aerosol-generating articles into the longitudinal channels.

[0155] Example Ex73: The system of any one of Examples Ex70 to Ex72, further comprising a transfer hopper configured to receive the aerosol-generating articles from the auxiliary belt and to collect the aerosol-generating articles substantially parallel to one another.

[0156] Example Ex74: The system of Example Ex73, further comprising a secondary belt, running substantially perpendicular to the auxiliary belt, configured to collect longitudinally- approaching aerosol-generating articles and to convey the aerosol-generating articles to the transfer hopper where the aerosol-generating articles are temporarily held substantially parallel to one another before being dispensed onto the alignment belt.

[0157] Example Ex75: The system of any one of Examples Ex63 to Ex74, wherein the transverse grooves of the alignment belt have a length greater than a length of the aerosolgenerating articles.

[0158] Example Ex76: The system of Example Ex75, further comprising a sensor configured to determine an orientation of each aerosol-generating article within its respective transverse groove.

[0159] Example Ex77: The system of Example Ex76, wherein the sensor is an optical sensor.

[0160] Example Ex78: The system of Example Ex76 or Ex77, wherein the sensor is an image sensor.

[0161] Example Ex79: The system of any one of Examples Ex76 to Ex78, wherein the sensor is a pattern recognition sensor configured to identify specific patterns on the at least one circumferential wrapper.

[0162] Example Ex80: The system of any one of Examples Ex76 to Ex79, wherein the sensor is configured to determine whether the first end plug portion of a given aerosol-generating article is closer than the second end plug portion to the first side edge of the alignment belt or whether the first end plug portion is closer than the second end plug portion to the second side edge of the alignment belt.

[0163] Example Ex81 : The system of Example Ex80, further comprising an air jet configured to move the aerosol-generating articles within the transverse grooves, on the basis of the orientation determined by the sensor, so that the first end plug portions abut the respective first or second opposed side edges of the alignment belt.

[0164] Example Ex82: The system of Example Ex80, further comprising an electromechanical actuator configured to move the aerosol-generating articles within the transverse grooves, on the basis of the orientation determined by the sensor, so that the first end plug portions abut the respective first or second opposed side edges of the alignment belt.

[0165] Example Ex83: The system of any one of Examples Ex63 to Ex82, wherein the cutters configured to cut the aerosol-generating articles at at least two points along a length of the aerosol-generating articles comprise a pair of rotating blades configured to separate the aerosol-generating substrate portion from the first end plug portion and the second end plug portion.

[0166] Example Ex84: The system of Example Ex83, wherein a first pair of rotating blades is provided adjacent to the first side of the alignment belt and a second pair of rotating blades is provided adjacent to the second side of the alignment belt. Example Ex85: The system of Example Ex83 or Ex84, wherein the rotating blades are spaced from each other along an axis of rotation by a distance corresponding to a length of the aerosol-generating substrate portion.

[0167] Example Ex86: The system of any one of Examples Ex83 to Ex85, wherein the alignment belt is provided with recesses configured to receive cutting edges of the rotating blades so as to allow a complete cut-through of the aerosol-generating articles in the transverse grooves.

[0168] Example Ex87: The system of any one of Examples Ex83 to Ex86, wherein the rotating blades of each pair of rotating blades are substantially parallel to each other.

[0169] Example Ex88: The system of any one of Examples Ex83 to Ex87, wherein the rotating blades of each pair of rotating blades share an axis of rotation.

[0170] Example Ex89: The system of any one of Examples Ex83 to Ex88, wherein the rotating blades have toothed cutting edges.

[0171] Example Ex90: The system of any one of Examples Ex83 to Ex88, wherein the rotating blades have smooth cutting edges.

[0172] Example Ex91 : The system of any one of Examples Ex83 to Ex90, wherein each rotating blade has a cutting width that is greater than a maximum spacing between the first plug end portion and the aerosol-generating substrate portion or greater than a maximum spacing between the second plug end portion and the aerosol-generating substrate portion.

[0173] Example Ex92: The system of any one of Examples Ex83 to Ex91 , wherein a mutual spacing of the rotating blades in each pair of rotating blades is adjustable.

[0174] Example Ex93: The system of Example Ex92, further comprising a control unit configured to adjust the mutual spacing in response to input parameters relating to a type of aerosol-generating article being processed.

[0175] Example Ex94: The system of Example Ex92, further comprising a sensing unit configured to determine a length of each aerosol-generating substrate portion and a control unit configured to adjust the mutual spacing in response the determined length of each aerosol-generating substrate portion.

[0176] Example Ex95: The system of any one of Examples Ex83 to Ex94, wherein a cutting angle of the rotating blades is adjustable.

[0177] Example Ex96: The system of Example Ex95, further comprising a control unit configured to adjust a cutting angle of the rotating blades in response to input parameters relating to a type of aerosol-generating article being processed.

[0178] Example Ex97: The system of any one of Examples Ex63 to Ex96, wherein the alignment belt is configured to hold the aerosol-generating articles in place in the transverse grooves during cutting. Example Ex98: The system of Example Ex97, wherein the transverse grooves in the alignment belt are provided with suction holes to hold the aerosol-generating articles in place in the transverse grooves during cutting.

[0179] Example Ex99: The system of Example Ex97, further comprising a clamping roller to hold the aerosol-generating articles in place in the transverse grooves during cutting.

[0180] Example Ex100: The system of any one of Examples Ex63 to Ex99, further comprising at least one vacuum extractor configured to extract debris from cutting the aerosol-generating articles.

[0181] Example Ex101 : The system of Example Ex100, wherein the at least one vacuum extractor comprises an adjustable nozzle.

[0182] Example Ex102: The system of any one of Examples Ex63 to Ex101 , wherein the first separator is configured to separate the first end plug portions, the second end plug portions and the aerosol-generating substrate portions from one another.

[0183] Example Ex103: The system of Example Ex102, wherein the alignment belt is configured to displace the first end plug portions from the alignment belt to a first end plug portion collection receptacle.

[0184] Example Ex104: The system of Example Ex102 or Ex103, wherein the alignment belt is configured to displace the second end plug portions from the alignment belt to a second end plug portion collection receptacle.

[0185] Example Ex105: The system of any one of Examples Ex102 to Ex104, wherein the first separator comprises a pneumatic ejector configured to displace the first end plug portions or the second end plug portions from the alignment belt.

[0186] Example Ex106: The system of any one of Examples Ex63 to Ex105, wherein the second separator comprises a pneumatic ejector configured to apply an air jet to blow the aerosolgenerating substrate portions, including the metallic susceptors, longitudinally out of their circumferential wrappers.

[0187] Example Ex107: The system of any one of Examples Ex63 to Ex105, wherein the second separator comprises a cutter configured to cut the circumferential wrappers along a length of the aerosol-generating substrate portions.

[0188] Example Ex108: The system of any one of Examples Ex63 to Ex107, wherein the cutter of item vii) is configured to cut the aerosol-generating substrate portions along their lengths to expose the metallic susceptors.

[0189] Example Ex109: The system of any Example Ex108, wherein the cutter of item vii) is a side-cutting knife.

[0190] Example Ex110: The system of any one of Examples Ex63 to Ex109, further comprising, between items vii) and viii), a vibrating surface configured to promote disentanglement of the metallic susceptors from aerosol-generating substrate of the aerosol-generating substrate portions.

[0191] Example Ex111 : The system of Example Ex110, wherein the vibrating surface comprises a sieve.

[0192] Example Ex112: The system of any one of Examples Ex63 to Ex111 , wherein the magnet is incorporated in a magnetic conveyor configured to convey aerosol-generating substrate of the aerosol-generating substrate portions and the metallic susceptors.

[0193] Example Ex113: The system of Example Ex112, wherein the magnetic conveyor comprises an endless driven belt with a magnetic roller at one end.

[0194] Example Ex114: The system of Example Ex112 or Ex113, wherein the magnetic roller is configured to retain the metallic susceptors on the endless belt as the endless belt passes around the magnetic roller while allowing the aerosol-generating substrate to fall into an aerosol-generating substrate collection receptacle.

[0195] Example Ex115: The system of Example Ex114, wherein the magnetic roller and the endless belt are configured to cause the metallic susceptors to fall from an underside of the endless belt as the metallic susceptors are conveyed away from the magnetic roller.

[0196] Example Ex116: The system of Example Ex115, further comprising a metallic susceptor collection receptacle into which the metallic susceptors fall from the underside of the endless belt.

[0197] Example Ex117: The system of any one of Examples Ex113 to Ex116, wherein the magnetic roller comprises at least one electromagnet.

[0198] Example Ex118: The system of any one of Examples Ex113 to Ex117, wherein the magnetic roller comprises at least one permanent magnet.

[0199] Example Ex119: The system of any one of Examples Ex63 to Ex111 , wherein aerosolgenerating substrate of the aerosol-generating substrate portions and the metallic susceptors are conveyed on a first conveyor, and wherein the magnet is incorporated in an over-band magnetic conveyor that passes over the first conveyor.

[0200] Example Ex120: The system of Example Ex119, wherein the magnet of the over-band magnetic conveyor is disposed over the first conveyor so as to cause the metallic susceptors to lift away from the first conveyor and to be conveyed away from the first conveyor on an underside of the over-band magnetic conveyor.

[0201] Example Ex121 : The system of Example Ex119 or Ex120, wherein the over-band magnetic conveyor is configured to convey the metallic susceptors to a metallic susceptor collection receptacle.

[0202] Example Ex122: The system of any one of Examples Ex119 to Ex121 , wherein the magnet of the over-band conveyor comprises an electromagnet. Example Ex123: The system of any one of Examples Ex119 to Ex121 , wherein the magnet of the over-band conveyor comprises a permanent magnet.

[0203] Examples will now be further described with reference to the figures in which:

[0204] Figure 1 shows, in schematic form, a longitudinal cross-section through an aerosolgenerating article;

[0205] Figure 2 shows, in schematic form, a process for separating components of the aerosolgenerating article of Figure 1 ;

[0206] Figure 3 shows, in schematic form, a plan view of a vibrating sieve;

[0207] Figure 4 shows, in schematic form, a plan view of an auxiliary belt;

[0208] Figure 5 shows, in schematic form, an end of the auxiliary belt of Figure 4 feeding aerosolgenerating articles onto a secondary belt;

[0209] Figure 6 shows, in schematic form, a side elevation cross section through a transfer hopper arranged between the secondary belt of Figure 5 and an alignment belt;

[0210] Figure 7 shows, in schematic form, a plan view of the alignment belt;

[0211] Figure 8 shows a rotating blade of an aerosol-generating article cutter; and

[0212] Figure 9 shows, in schematic form, a magnetic separator.

[0213] Figure 1 shows a longitudinal cross-section through an exemplary aerosol-generating article

[0214] 1 incorporating five distinct components or segments arranged in coaxial alignment: a first end plug portion 10, an aerosol-generating substrate portion 11 with a metallic susceptor 12, a hollow acetate tube (HAT) filter 13, a fine hollow acetate tube (FHAT) filter 14, and a mouthpiece filter 15. The HAT filter 13, FHAT filter 14 and the mouthpiece filter 15 may together form a second end plug portion 19. These components are arranged sequentially and are tightly contained within an outer wrapper 16 and tipping paper 18 to form a cylindrical rod. In the illustrated example, the metallic susceptor 12 has the form of a flat ribbon, although other form factors may be implemented.

[0215] Exemplary dimensions and materials of the various components are set out in Tables 1 and

[0216] 2 above.

[0217] The design of an aerosol-generating article 1 adheres to precise manufacturing specifications. However, during the manufacturing and assembly processes of an aerosolgenerating article 1 , deviations in segment dimensions and variations in the output of the assembly equipment may lead to discrepancies within the specifications of the final product. In some instances, these variations can result in gaps 17, for example between the front end plug portion 10 and the aerosol-generating substrate portion 11 , or between the second end plug portion 19 and the aerosol-generating substrate portion 11 . For example, when fully assembled, the aerosol-generating substrate portion 11 might be slightly displaced from its ideal position and the assembly equipment is typically configured to continuously monitor these process parameters and take appropriate action depending on whether the finished aerosol-generating article 1 is acceptable according to predefined tolerance targets. If not, the aerosol-generating article 1 may be rejected. Furthermore, other aerosol-generating articles 1 , whether finished or part-finished, may be rejected from the manufacturing process during initial packaging stages due to packaging deformities or else rejected immediately after formation of the initial aerosol-generating substrate portion 11 produced after crimping of the aerosol-generating substrate materials.

[0218] In any case, aerosol-generating articles 1 failing to meet the necessary quality standards are considered defective and need to be removed before the final packaging stage of the final product. Afterwards, to minimize waste and maximize resources, it is common practice to recover the more valuable components from these rejected aerosol-generating articles 1 , in particular aerosol-generating substrates containing nicotine or tobacco, or metallic susceptors 12, or both aerosol-generating substrates and metallic susceptors 12, for recycling or reintroduction into the manufacturing process.

[0219] Aspects of the present innovation may relate to a recovery process that addresses the limitations of existing systems by implementing precise control over the separation and recovery of individual constituents from aerosol-generating articles 1 , for example “heat-not-burn” tobacco articles. The recovery process comprises the steps of vibrating a bulk quantity of aerosolgenerating articles, aligning individualized aerosol-generating articles in a traversal direction by means of an alignment belt, monitoring the precise orientation of an aerosol-generating article by means of a sensing unit, cutting an aerosol-generating article into individual segments by means of a precision cutter, and separating an aerosol-generating substrate, for example a tobacco or nicotine substrate, from a metallic susceptor by means of a magnet.

[0220] In an embodiment, the process involves a conveying system integrating multiple machines for transferring, sorting, and separating an aerosol-generating article. A vibrating sieve removes undesirable elements, ensuring only clean and properly-sized aerosol-generating articles proceed to the cutting phase. Furthermore, an alignment belt, in cooperation with positioning means, ensures proper alignment of aerosol-generating articles regardless of their orientation upon loading. Afterwards, a cutting operation is performed by precision cutters equipped with multiple rotary blades. The precision cutters engage the aerosol-generating article at specific points along its length, matching the ends of an aerosol-generating substrate portion. The cutting width of the blades may be carefully selected to prevent cross-contamination and ensure precise cuts.

[0221] To minimize cross-contamination, an extraction system may be provided to remove debris from the cutting process. Vacuum extractors may be directed to capture ejected debris from the rotary blades, ensuring clean and efficient operation. Furthermore, the recovery process includes a magnetic separator, which effectively separates metallic susceptors from the conveyed blend of aerosol-generating substrate and metallic susceptors. This step ensures proper management of each component for subsequent processing. Embodiments of the present innovation address the limitations of some current systems by introducing a recovery process designed for aerosol-generating articles adapted for induction heating by way of a metallic susceptor. By incorporating a precision cutter in conjunction with extraction machinery, there is a reduced risk of cross-contamination during the recovery process. Moreover, the inclusion of a magnetic separator enables efficient recycling of aerosol-generating articles adapted for induction heating. Embodiments of the invention may enhance the overall efficiency of the recovery process, resulting in a higher recovery yield that aligns with regulatory frameworks and sustainability standards.

[0222] Figure 2 shows, in schematic form, an exemplary recovery process according to an embodiment of the present invention. The process is directed towards separating an aerosolgenerating article 1 into its constituent components.

[0223] During manufacturing of aerosol-generating articles, a quantity of rejected aerosolgenerating articles 1 are transferred to a facility where a recovery process 2 can be carried out. Referring to Figure 2, the recovery process 2 is performed by a conveying system 20 integrating multiple machines for transferring, sorting, and separating an aerosol-generating article 1 into its constituent components. In general, the conveying system 20 may integrate a belt conveyor employing a continuous loop to guide and transfer the aerosol-generating articles 1 along a longitudinal processing path. Alternatively, the conveying system 20 might integrate a roller conveyor that uses a series of cylindrical rollers to displace the aerosol-generating articles 1 . It will be appreciated that for each step during the recovery process, a different suitable conveyor can be used. In this sense, different modular conveyors might also adapt to the specific requirements for each step along the processing path.

[0224] The recovery process 2 begins by feeding a bulk 21 of aerosol-generating articles 1 into the conveying system 20. In a particular embodiment, for this step, a collecting hopper 22, is provided for collecting and acting as a buffer, dispensing small quantities of aerosol-generating articles 1 from the bulk 21. The collecting hopper 22 may incorporate vibrators such as electromechanical shakers for vibrating the bulk 21 . Aerosol-generating articles 1 , especially if transported in bulk, meaning tightly packed, may entangle with each other. Some aerosol-generating articles 1 may not be straight and form a curved shape that hooks adjacent aerosol-generating articles 1 , impeding the smooth flow of individual aerosol-generating articles 1 and leading to interruptions in the recovery process. By vibrating the bulk 21 , the collecting hopper 22 disentangles the aerosol-generating articles 1 , ensuring a consistent and continuous flow of individual aerosolgenerating articles 1 along the further processing steps of the recovery process 2.

[0225] After loosening and individualizing the bulk 21 of aerosol-generating articles 1 , a vibrating sieve 23 downstream from the collecting hopper 22 receives small batches of aerosol-generating articles 1 from the collecting hopper 22 in a controlled manner. In a particular embodiment, a controlled dispensing from the collecting hopper 22 is supported by a vertical conveyor with shelf partitions adapted to receive an output load from the collecting hopper 22. Vertical conveyors, also known as lift conveyors, may enable efficient utilization of available vertical space within a processing facility. The vertical conveyor unloads the small batches of aerosol-generating articles 1 along the vibrating sieve 23, aimed towards removing unwanted elements from the recovery process.

[0226] As shown in Figure 3, a vibrating sieve 23 may be configured as a wire mesh integrating a grid-like structure with small openings 230.

[0227] In a further preferred embodiment, the vibrating sieve 23 may incorporate a mechanical shaker for providing controlled vibrations to the aerosol-generating articles 1. These vibrations are characterized by specific amplitude and frequency, which are set to ensure optimal separation of the aerosol-generating articles 1 from undesirable waste or foreign particles. For example, the optimal amplitude range may be between 1mm to 6mm, more preferably 3 to 4mm. For example, the optical optimal frequency may be between 5 to 100Hz, more preferably 30 to 60Hz.

[0228] The amplitude, which refers to the size of the vibration, and the frequency, which is the rate at which the vibrating sieve 23 vibrates, may be tuned to ensure that the smaller waste materials fall through the openings 230 into a designated waste container, while the larger, clean, and properly-sized aerosol-generating articles 1 are unable to pass through the mesh.

[0229] The frequency of the vibrations may be set to a high value, to ensure rapid separation of waste, while the amplitude may be kept at a moderate level, to prevent damage to the aerosolgenerating articles. In addition to this, the direction and pattern of the vibrations can also be adjusted to promote uniform distribution of the aerosol-generating articles across the vibrating sieve 23 and prevent clustering.

[0230] Continuing with the recovery process in Figure 2, before a cutting operation, the recovery process may integrate machinery for aligning the aerosol-generating articles 1 longitudinally with the direction of travel for conveying to the cutting step. In a particular embodiment, the vibrating sieve 23 transports the individual aerosol-generating articles 1 towards an auxiliary belt 300 as shown in Figure 4.

[0231] Figure 4 is a schematic plan view of the aerosol-generating articles 1 passing across the vibrating sieve 23 in substantially random orientations. The aerosol-generating articles 1 then pass onto the auxiliary belt 300. The auxiliary belt 300 includes parallel running tracks forming individual channels to receive the incoming aerosol-generating articles 1 from the vibrating sieve 23. In this way, every aerosol-generating article 1 loaded within the auxiliary belt is directed longitudinally along the conveyed motion. For instance, a brush 305, which may be a rotating brush, can be arranged across a longitudinal direction of travel of the auxiliary belt 300. The brush 305 can guide the aerosol-generating articles 1 into the individual channels so that the aerosol-generating articles 1 are all aligned substantially parallel to each other and with the longitudinal direction of travel. The brush 305 can be used in cooperation with mechanical guides to ensure individual aerosol-generating articles 1 are properly loaded into the channels. The brush 305 may be mounted on a motorized arm or conveyor system, and bristles of the brush 305 can be designed to gently guide the aerosol-generating articles 1 into the channels.

[0232] Figure 5 is a schematic plan view of a downstream end of the auxiliary belt 300. The aerosol-generating articles 1 in the individual channels are fed onto a secondary belt 301 that has a direction of travel that is substantially perpendicular to that of the auxiliary belt 300. It will be seen that the aerosol-generating articles 1 on the secondary belt 301 are arranged substantially parallel to each other, but are now disposed in an orientation substantially perpendicular to the direction of travel. The longitudinal ends of the aerosol-generating articles 1 are also generally aligned, although it will be noted that the aerosol-generating articles 1 can each take one of two possible orientations - either with the first end plug portion on the left of the secondary belt 301 (relative to the direction of travel), or with the first end plug portion on the right of the secondary belt 301 (relative to the direction of travel).

[0233] Afterwards, a transfer hopper may be provided for collecting the oncoming longitudinally- aligned aerosol-generating articles 1 in parallel. In a particular embodiment, shown in Figure 6, the secondary belt 301 , running perpendicular to the auxiliary belt 300, collects the oncoming longitudinally-aligned aerosol-generating articles 1 and stores them within a transfer hopper 302 adapted for controlled dispensing of individual aerosol-generating articles 1 . The transfer hopper 302 may provide both a buffering function and a dispensing function. The transfer hopper 302 may be configured to dispense aerosol-generating articles 1 onto an alignment belt 25 as will be described in detail hereinbelow.

[0234] As a final step towards aligning the aerosol-generating articles 1 for traversal to a cutting operation, the transfer hopper 302 may be adapted for loading single aerosol-generating articles 1 into specific receptacles of an alignment belt 25 as shown in Figure 7. In the embodiment depicted in Figure 7, the alignment belt 25 is designed with multiple transverse trough-shaped receptacles or transverse grooves 250. These receptacles 250 have a greater longitudinal dimension than the aerosol-generating articles 1 . This enables the transfer hopper to load the aerosol-generating articles 1 within the receptacles 250. and transport them towards a first side edge 251 of the alignment belt 25. During transfer, the aerosol-generating articles 1 can be oriented in either of two ways: with the first end plug portion 10 facing the first side edge 251 of the alignment belt 25 or with the second end plug portion 19 facing the first side edge 251 of the alignment belt 25.

[0235] In a particular embodiment, the alignment belt 25 is configured to convey a stream of aerosol-generating articles 1 perpendicular to their longitudinal direction in the conveying direction X, which is in turn the preferred direction for the cutting operation. Shortly after an aerosolgenerating article 1 is loaded, a sensing unit 31 , preferably placed on an edge of the alignment belt 25, is employed to detect the precise orientation of an aerosol-generating article 1 within the receptacle 250, as shown in Figure 7. This sensing unit 31 can be an optical sensor, for example an image sensor. In a preferred embodiment, the sensing unit 31 includes a pattern recognition sensor that identifies specific patterns printed on the outer wrapper of the aerosol-generating article 1. By executing image analysis and pattern recognition algorithms, the sensing unit 31 can accurately determine the orientation of the aerosol-generating article 1 by comparing the detected pattern with stored reference patterns.

[0236] If the sensing unit 31 detects a second end plug portion 19 instead of a first end plug portion 10, the aerosol-generating article 1 is displaced towards the second side edge 252 of the alignment belt 25 by way of a positioning mechanism 32. The positioning mechanism 32 can be for example an air blowing device or an electromechanical actuator that gently pushes the aerosol-generating article 1 to the second side edge 252. With this alignment, independent of their orientation, aerosol-generating articles 1 can be transported by the alignment belt 25 towards precision cutters 26A, 26B, which are configured to cut through the aerosol-generating articles 1 . In an embodiment, the precision cutters 26A, 26B are positioned on both sides of the alignment belt 25, a first precision cutter 26A for the stream of aerosol-generating articles 1 travelling adjacent to the first side edge 251 and a second precision cutter 26B for the stream of aerosolgenerating articles 1 travelling adjacent to the second side edge 252. It should be noted that while this embodiment utilizes two precision cutters 26A, 26B on both sides of the alignment belt 25, the number of precision cutters can vary as needed.

[0237] In a particular embodiment, each precision cutter 26A, 26B aims at separating the aerosolgenerating substrate portion 11 from the first plug end portion 10 and the second plug end portion 19. For this, the precision cutters 26A, 26B are configured to engage the aerosol-generating article 1 at two distinct points along its length, matching the ends of the aerosol-generating substrate portion 11 . For this, each precision cutter 26A, 26B is equipped with two parallel rotary blades 40, 41 , with cutting planes matching the ends of the aerosol-generating substrate portion 11 in the aerosol-generating article 1. To achieve a complete cut-through, the alignment belt 25 includes recesses 253 through which cutting edges of the rotary blades 40, 41 can protrude. In an exemplary embodiment shown in Figure 8, a rotary blade 40, 41 comprises a circular or disc blade having a notched or toothed circumferential cutting edge 42.

[0238] Furthermore, to achieve a precise cutting that prevents cross-contamination to the highest extent, a precision cutter 26A, 26B should ensure that its cutting width is always greater than the largest possible gap 17 between segments and the largest deviation from its centred cutting position. This may be achieved by selecting a cutting blade 40, 41 with a width that considers the maximum gap tolerances to which the aerosol-generating articles 1 are manufactured, and the maximum displacement that an aerosol-generating article 1 may experience from its centred position within the receptacle 250. For example, a maximum possible gap 17 between segments of an aerosol-generating article 1 may be specified as 10 micrometres, and a maximum deviation of an aerosol-generating article 1 from its centred position within the receptacle 250 as 10 micrometres. In such case, a blade part 40, 41 of the precision cutter 26A, 26B may be designed with a cutting width of 20 micrometres. In practice, the cutting width dimensions may also consider other manufacturing tolerances of the cutting equipment or the alignment belt 25.

[0239] In further embodiments, the aerosol-generating article 1 may be held in place in its receptacle 250 by additional devices during the cutting operation. For example, just before reaching the rotary blade 40, 41 , a clamping roller (not shown) preceding the precision cutter 26A, 26B may slightly press against the aerosol-generating article 1 during cutting.

[0240] In an embodiment, based on predefined input parameters regarding a specific type of aerosol-generating article 1 , the precision cutter 26A, 26B may perform a pre-set adjustment to perform a cutting operation more precisely. In an embodiment, the precision cutter 26A, 26B connects to a control unit adapted to receive input parameters related to a type of aerosolgenerating article 1 . In this way, prior to initiating the recovery process, an operator can input a set of parameters corresponding to the type of aerosol-generating articles 1 to be processed. These parameters include the desired length of each component segment, the acceptable tolerance for variations in segment length, and the preferred orientation for cutting (for example, perpendicular to the length of the aerosol-generating article 1 , or at an angle). In this way, a precision cutter 26A, 26B may calibrate itself for the specific type of aerosol-generating article 1 to be cut, or a control device may indicate the operator to perform a manual calibration (e.g., by replacing one precision cutter 26A, 26B for a different precision cutter 26A, 26B).

[0241] To further minimize cross-contamination, an extraction system can be configured to remove any by-products from the cutting process promptly and efficiently. For instance, referring to Figure 7, vacuum extractors 51 can be oriented to capture any debris ejected from the rotary blade 40, 41 during the cutting operation. Extraction systems designed for this purpose may include a nozzle that can be precisely positioned to optimize debris capture. This nozzle, which may be adjustable, is directed towards the cutting area to ensure maximum extraction efficiency.

[0242] Continuing with the recovery process, the cut and segmented aerosol-generating articles 1 are further sorted into different pathways after the cutting operation. In an embodiment, a sorting unit 27 separates the aerosol-generating substrate portion 11 from the first end plug portion 10 and the second end plug portion 19. For example, the sorting unit 27 may employ a pneumatic ejector that operates by directing a high-speed gas flow to propel the first end plug portion 10 outwards from the alignment belt 25 into a designated container 30. Similarly, a pneumatic ejector may propel the second end plug portion 19 (for example, comprising the mouthpiece filter 15, together with the HAT 13 and FHAT 14) towards another designated container 30. After this, a mechanical actuator may be designated to displace the aerosol-generating substrate portion 11 towards a blower that ejects the aerosol-generating substrate with the metallic susceptor 12 from the outer wrapper 16. At this stage, the aerosol-generating substrate and the metallic susceptor 12 form a blend that may undergo further processing 29 for disentanglement. A side-cutting knife can be used to cut open the aerosol-generating substrate to release or expose the metallic susceptor 12 core material. An additional conveyor with a vibrating sieve may be used for further disentanglement of the metallic susceptor 12 from fibres within the aerosol-generating substrate.

[0243] Referring now to Figure 9, a magnetic separator 29 can be positioned to magnetically separate the metallic susceptor 12 from the conveyed blend 60 of aerosol-generating substrate and metallic susceptors. In one embodiment, a magnetic separator is a magnetic conveyor 70. As illustrated in Figure 9, when the conveyed blend 60 reaches an arc portion 71 of the magnetic conveyor 70, the magnetic force from an arrangement of electromagnets 72 retains the metallic susceptors against the surface of the magnetic conveyor 70. This retention continues until the blend 60 reaches the end of the arc portion 71. At this point, the magnetic attraction from the electromagnets 72 is not enough to hold the metallic susceptors and a guiding wall 73 assists their downstream travel towards a designated container. In contrast, the aerosol-generating substrate fibres, which do not experience attraction from the electromagnets 72, are influenced by gravity and fall towards a separate container. This process effectively separates the metallic susceptors from the aerosol-generating substrate fibres, ensuring each component can be appropriately managed afterwards. In an alternative embodiment, the magnetic separator may be an over-band magnetic conveyor.

[0244] For the purpose of the present description and of the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term "about". Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein. In this context, therefore, a number A is understood as A ± 5% of A. Within this context, a number A may be considered to include numerical values that are within general standard error for the measurement of the property that the number A modifies. The number A, in some instances as used in the appended claims, may deviate by the percentages enumerated above provided that the amount by which A deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein.

Claims

CLAIMS:

1. A method of processing rod-shaped consumable aerosol-generating articles each comprising an aerosol-generating substrate portion including a metallic susceptor, the aerosol-generating generating substrate being longitudinally disposed between first end and second end plug portions, the aerosol-generating substrate and the first and second end plug portions being wrapped in at least one circumferential wrapper, the method comprising the steps of: i) feeding the aerosol-generating articles onto a vibrating sieve and causing the aerosol-generating articles to pass across a surface of the vibrating sieve; ii) arranging the aerosol-generating articles, after passage across the surface of the vibrating sieve, on an alignment belt comprising a plurality of transverse grooves configured to receive the aerosol-generating articles aligned substantially parallel to each other, the alignment belt having first and second opposed side edges; iii) positioning the aerosol-generating articles within the transverse grooves such that the first end plug portions abut at least one of the first and second opposed side edges of the alignment belt; iv) cutting the aerosol-generating articles at at least two points along a length of the aerosol-generating articles so as to separate the first end and second end plug portions from the aerosol-generating substrate portion; v) separating the aerosol-generating substrate portions from the first end plug portions and the second end plug portions; vi) separating the aerosol-generating substrate portions, including the metallic susceptors, from their circumferential wrappers; vii) cutting the aerosol-generating substrate portions so as to expose the metallic susceptors; viii) applying a magnetic field so as to separate the metallic susceptors from the aerosol-generating substrate portions; and ix) separately collecting the aerosol-generating substrate portions and the metallic susceptors.

2. The method of claim 1 , wherein prior to step i), the aerosol-generating articles are collected in a collecting hopper, and wherein the aerosol-generating articles are vibrated in the collecting hopper before being controllably fed to the vibrating sieve.

3. The method of claim 1 or 2, wherein after step i) and prior to step ii), the aerosolgenerating articles are conveyed on an auxiliary belt comprising substantially parallel tracksrunning at different speeds so as to align the aerosol-generating articles longitudinally with a direction of travel.

4. The method of claim 3, wherein the aerosol-generating articles are transferred from the auxiliary belt to a transfer hopper configured to collect the aerosol-generating articles substantially parallel to one another.

5. The method of any one of claims 1 to 4, wherein in step ii), the transverse grooves of the alignment belt have a length greater than a length of the aerosol-generating articles, and wherein the alignment belt includes a sensor to determine an orientation of each aerosolgenerating article within its respective transverse groove.

6. The method of any one of claims 1 to 5, wherein in step iv), each aerosol-generating article is cut by a pair of rotating blades so as to separate the aerosol-generating substrate portion from the first end plug portion and the second end plug portion.

7. The method of claim 6, wherein each rotating blade has a cutting width that is greater than a maximum spacing between the first plug end portion and the aerosol-generating substrate portion or greater than a maximum spacing between the second plug end portion and the aerosol-generating substrate portion.

8. The method of any one of claims 1 to 7, wherein in step viii), aerosol-generating substrate of the aerosol-generating substrate portions and the metallic susceptors are conveyed on a magnetic conveyor, wherein the magnetic conveyor comprises an endless driven belt with a magnetic roller at one end, and wherein the magnetic roller retains the metallic susceptors on the endless belt as the endless belt passes around the magnetic roller while allowing the aerosol-generating substrate to fall into an aerosol-generating substrate collection receptacle.

9. A system for processing rod-shaped consumable aerosol-generating articles each comprising an aerosol-generating substrate portion including a metallic susceptor, the aerosol-generating generating substrate being longitudinally disposed between first end and second end plug portions, the aerosol-generating substrate and the first and second end plug portions being wrapped in at least one circumferential wrapper, the system comprising: i) a vibrating sieve configured to receive the aerosol-generating articles, the vibrating sieve having a surface across which the aerosol-generating articles are passed;ii) an alignment belt comprising a plurality of transverse grooves configured to receive the aerosol-generating articles aligned substantially parallel to each other, the alignment belt having first and second opposed side edges; iii) actuators configured to position the aerosol-generating articles within the transverse grooves such that the first end plug portions abut at least one of the first and second opposed side edges of the alignment belt; iv) cutters configured to cut the aerosol-generating articles at at least two points along a length of the aerosol-generating articles so as to separate the first end and second end plug portions from the aerosol-generating substrate portion; v) a first separator configured to separate the aerosol-generating substrate portions from the first end plug portions and the second end plug portions; vi) a second separator configured to separate the aerosol-generating substrate portions, including the metallic susceptors, from their circumferential wrappers; vii) a cutter configured to cut the aerosol-generating substrate portions so as to expose the metallic susceptors; and viii) a magnet configured to apply a magnetic field so as to separate the metallic susceptors from the aerosol-generating substrate portions.

10. The system of claim 9, further comprising a collecting hopper configured to collect the aerosol-generating articles prior to passage across the surface of the vibrating sieve, and wherein the collecting hopper is configured to vibrate the aerosol-generating articles and controllably to feed the aerosol-generating articles to the vibrating sieve.11 . The system of claim 9 or 10, further comprising an auxiliary belt having substantially parallel tracks running at different speeds so as to align the aerosol-generating articles longitudinally with a direction of travel.

12. The system of claim 11 , further comprising a transfer hopper configured to receive the aerosol-generating articles from the auxiliary belt and to collect the aerosol-generating articles substantially parallel to one another.

13. The system of any one of claims 9 to 12, wherein the transverse grooves of the alignment belt have a length greater than a length of the aerosol-generating articles, and wherein the system further comprises a sensor configured to determine an orientation of each aerosol-generating article within its respective transverse groove.

14. The system of any one of claims 9 to 13, wherein the cutters configured to cut the aerosol-generating articles at at least two points along a length of the aerosol-generating articles comprise a pair of rotating blades configured to separate the aerosol-generating substrate portion from the first end plug portion and the second end plug portion.

15. The system of any one of claims 9 to 14, wherein the magnet is incorporated in a magnetic conveyor configured to convey aerosol-generating substrate of the aerosolgenerating substrate portions and the metallic susceptors, wherein the magnetic conveyor comprises an endless driven belt with a magnetic roller at one end, and wherein the magnetic roller is configured to retain the metallic susceptors on the endless belt as the endless belt passes around the magnetic roller while allowing the aerosol-generating substrate to fall into an aerosol-generating substrate collection receptacle.

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