Smokeless Dissolvable Compressed Tobacco Pasteurization
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Solution Overview
Problem
Raw tobacco products contain high levels of viable bacteria, which pose a risk when ingested in smokeless dissolvable compressed tobacco products, as they dissolve and are ingested by consumers, necessitating an improved method for reducing microbial contamination.
Innovation Solution
Pasteurizing the tobacco component by direct heating with hot steam injection to reduce aerobic microbial and yeast/mold counts, then mixing and compressing it with non-tobacco components to create a smokeless dissolvable compressed tobacco product, while adjusting pH and incorporating additives like sodium chloride and flavorants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If raw tobacco is used in smokeless dissolvable compressed tobacco products, then the product maintains natural tobacco characteristics and flavor, but high levels of viable bacteria and microbial contamination pose safety risks to consumers
Solution Approach 1:
The patent applies preliminary pasteurisation treatment to the tobacco component before mixing it with other ingredients and compressing it into the final product. This advance treatment reduces microbial contamination to acceptable levels while preserving the tobacco's natural characteristics, ensuring consumer safety before the product reaches the consumer.
Solution Approach 2:
The patent changes the temperature parameter during processing by heating the tobacco component to between 60°C and 120°C during pasteurisation. This parameter change effectively reduces microbial contamination while maintaining the tobacco's functional properties and flavor characteristics, resolving the contradiction between safety and natural characteristics.
2Reliability
If pasteurisation is applied to reduce microbial counts, then consumer safety is improved, but additional processing steps and time are required
Solution Approach 1:
The patent combines the pasteurisation step with the existing mixing and compression process into a single integrated manufacturing flow. The tobacco component is pasteurised, then immediately mixed with other ingredients and compressed without separate handling steps, thereby reducing processing complexity while maintaining safety benefits.
3Reliability
If pasteurisation is applied to reduce microbial counts, then consumer safety is improved, but additional processing time is required
Solution Approach 1:
The patent performs pasteurisation as a preliminary step that integrates seamlessly into the manufacturing process, reducing microbial contamination to acceptable levels before the tobacco is mixed and compressed. This advance treatment prevents the need for additional safety checks or reprocessing later, thereby minimizing overall processing time while ensuring consumer safety.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method effectively reduces microbial counts to safe levels, creates aseptic tobacco products, and enhances flavor formation, ensuring consumer safety and product quality.
Implementation Method 1
The step of pasteurising the tobacco component comprises direct heating of the tobacco by hot steam injection to a temperature of between about 100°C and about 120°C for a period of between about 1 minute and about 30 minutes
Data Source
Figure 1(a)~12(c)
AI summary
A smokeless dissolvable compressed tobacco product having a total aerobic microbial count of less than 2 log cfu/g is made by pasteurising a tobacco component so as to reduce the total aerobic microbial count thereof to less than 2 log cfu/g and the total yeast and mould count thereof to less than 2 log cfu/g. The pasteurised tobacco component is mixed with one or more non-tobacco components before being compressed to form the smokeless dissolvable compressed tobacco product.