U.S. patent application number 12/014525 was filed with the patent office on 2008-07-24 for smokeless tobacco.
Invention is credited to Daniel Verdin Cantrell, James Neil Figlar, Darrell Eugene Holton, Laya Katina Palmer Horton, John-Paul Mua, Pankaj Patel, John Howard Robinson.
Application Number | 20080173317 12/014525 |
Document ID | / |
Family ID | 40481752 |
Filed Date | 2008-07-24 |
United States Patent
Application |
20080173317 |
Kind Code |
A1 |
Robinson; John Howard ; et
al. |
July 24, 2008 |
SMOKELESS TOBACCO
Abstract
A smokeless tobacco product is provided. A water-permeable pouch
containing a tobacco formulation and configured for insertion into
the mouth of a user of that product is provided. The tobacco
formulation includes granular tobacco and a buffer comprised of
sodium carbonate and sodium bicarbonate. An outer packaging
material enveloping the pouch is provided and is sealed so as to
allow a controlled environment to be maintained within.
Inventors: |
Robinson; John Howard;
(Kernersville, NC) ; Horton; Laya Katina Palmer;
(Winston Salem, NC) ; Patel; Pankaj; (Clemmons,
NC) ; Mua; John-Paul; (Advance, NC) ;
Cantrell; Daniel Verdin; (Lewisville, NC) ; Figlar;
James Neil; (Rural Hall, NC) ; Holton; Darrell
Eugene; (Clemmons, NC) |
Correspondence
Address: |
BRINKS HOFER GILSON & LIONE
P.O. BOX 10395
CHICAGO
IL
60610
US
|
Family ID: |
40481752 |
Appl. No.: |
12/014525 |
Filed: |
January 15, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11461628 |
Aug 1, 2006 |
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12014525 |
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11461633 |
Aug 1, 2006 |
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11461628 |
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Current U.S.
Class: |
131/112 ;
131/352 |
Current CPC
Class: |
B65D 81/266 20130101;
A24B 15/28 20130101; B65D 81/2084 20130101; B65D 77/003 20130101;
A24F 23/02 20130101; A24B 13/00 20130101; B65D 81/2076
20130101 |
Class at
Publication: |
131/112 ;
131/352 |
International
Class: |
A24B 1/10 20060101
A24B001/10; A24B 15/00 20060101 A24B015/00 |
Claims
1. A smokeless tobacco product comprising: a water-permeable pouch
containing a tobacco formulation and configured for insertion into
the mouth of a user of that product, the tobacco formulation
including granular tobacco and a buffer comprised of sodium
carbonate and sodium bicarbonate; and an outer packaging material
enveloping said pouch and being sealed so as to allow a controlled
environment to be maintained within.
2. The smokeless tobacco product of claim 1, wherein said
controlled environment consists of carbon dioxide.
3. The smokeless tobacco product of claim 1, wherein said
controlled environment consists essentially of carbon dioxide.
4. The smokeless tobacco product of claim 1, wherein said buffer is
comprised of sodium carbonate and sodium bicarbonate at a ratio of
between about 1:70 and 1:85.
5. The smokeless tobacco product of claim 1, wherein said buffer is
comprised of sodium carbonate and sodium bicarbonate at a ratio of
between about 1:20 and 1:99.
6. The smokeless tobacco product of claim 1, further comprising an
oxygen absorber contained within the outer packaging material.
7. The smokeless tobacco product of claim 1, further comprising an
oxygen and carbon dioxide absorber contained within the outer
packaging material.
8. A smokeless tobacco product comprising: a water-permeable pouch
containing a tobacco formulation and configured for insertion into
the mouth of a user of that product, the tobacco formulation
including granular tobacco and a buffer comprised of at least two
buffering elements; and an outer packaging material enveloping said
pouch and being sealed so as to allow a controlled environment to
be maintained within.
9. The smokeless tobacco product of claim 8, wherein said buffering
elements are sodium carbonate and sodium bicarbonate.
10. The smokeless tobacco product of claim 8, wherein said
buffering elements are sodium carbonate and ammonium
bicarbonate.
11. The smokeless tobacco product of claim 10, wherein the ratio of
sodium carbonate to ammonium bicarbonate is about 2:3.
12. The smokeless tobacco product of claim 8, wherein said
buffering elements are potassium hydroxide and sodium
bicarbonate.
13. The smokeless tobacco product of claim 12, wherein the ratio of
potassium hydroxide to sodium bicarbonate is about 1:75.
14. The smokeless tobacco product of claim 8, wherein said
buffering elements are sodium hydroxide and potassium
bicarbonate.
15. The smokeless tobacco product of claim 14, wherein the ratio of
sodium hydroxide to potassium bicarbonate is about 1:75.
16. The smokeless tobacco product of claim 8, wherein said
buffering elements are potassium hydroxide, sodium carbonate and
sodium bicarbonate.
17. The smokeless tobacco product of claim 16, wherein the ratio of
potassium hydroxide to sodium carbonate to sodium bicarbonate is
about 2:5:3.
18. The smokeless tobacco product of claim 8, wherein said
controlled environment consists of carbon dioxide.
19. The smokeless tobacco product of claim 8, wherein said
controlled environment consists essentially of carbon dioxide.
20. A smokeless tobacco product comprising: a plurality of
water-permeable pouches each configured for insertion into the
mouth of a user of the product and containing a tobacco
formulation, the tobacco formulation including granular tobacco and
a buffer comprised of at least two buffering elements, a hard
container encompassing said water-permeable pouches, and an outer
packaging material enveloping said hard container and being sealed
so as to allow a controlled environment to be maintained
within.
21. The smokeless tobacco product of claim 20, wherein said
controlled environment consists of carbon dioxide.
22. The smokeless tobacco product of claim 20, wherein said
controlled environment consists essentially of carbon dioxide.
23. The smokeless tobacco product of claim 20 wherein said hard
container can be opened and resealed to allow one or more of said
water permeable pouches to be dispensed as desired by the user.
24. The smokeless tobacco product of claim 23 wherein said hard
container is made of metal or plastic.
25. The smokeless tobacco product of claim 20 wherein said outer
packaging material is formed of two pieces of said material
superimposed in edge to edge contact, said edges being sealed by an
overlap seal.
26. A smokeless tobacco product comprising: a plurality of
water-permeable pouches containing a tobacco formulation and
configured for insertion into the mouth of a user of that product,
the tobacco formulation including granular tobacco and a buffer
comprised of at least two buffering elements; and a hard container
encompassing said water-permeable pouches, said hard container
being tightly sealed so as to allow a controlled environment to be
maintained within.
27. The smokeless tobacco product of claim 26, said hard container
comprising a lower portion and a separate, upper portion which
mates with said lower portion to form a closed container, and a
band of sealing material covering the mating surfaces of said upper
and lower portions.
28. The smokeless tobacco product of claim 26 wherein said
container is made of metal or plastic.
29. A smokeless tobacco product comprising: a plurality of
water-permeable pouches each containing a tobacco formulation and
configured for insertion into the mouth of a user of that product,
the tobacco formulation including granular tobacco and a buffer
comprised of at least two buffering elements; an outer packaging
material enveloping each of said pouches and being sealed so as to
allow a controlled environment to be maintained within; and a hard
container encompassing said water-permeable pouches enveloped by
said outer packaging material, said hard container being tightly
sealed so as to allow a controlled environment to be maintained
within.
30. The smokeless tobacco product of claim 29, said hard container
comprising a lower portion and a separate, upper portion which
mates with said lower portion to form a closed container, and a
band of sealing material covering the mating surfaces of said upper
and lower portions.
31. The smokeless tobacco product of claim 29 wherein said
container is made of metal or plastic.
32. The smokeless tobacco product of claim 29 wherein the
controlled environment maintained within said outer packaging
material enveloping each of said pouches is different from the
controlled environment maintained within said hard container.
33. A smokeless tobacco product comprising: a plurality of
water-permeable pouches each containing a tobacco formulation and
configured for insertion in the mouth of a user of that product,
the tobacco formulation including granular tobacco and a buffer
comprised of at least two buffering elements; an outer packaging
material enveloping each of said pouches and being sealed so as to
allow a controlled environment to be maintained within; a hard
container encompassing said water-permeable pouches enveloped by
said outer packaging material; and a second outer packaging
material enveloping said hard container and being sealed so as to
allow a controlled environment to be maintained within.
34. The smokeless tobacco product of claim 33 wherein the
controlled environment maintained within said outer packaging
material enveloping each of said pouches is different from the
controlled environment maintained within said second outer
packaging material.
35. A method of maintaining the pH producing ability of a smokeless
tobacco product over a period of time, said method comprising the
steps of: adding a buffer comprising at least two elements to a
tobacco formulation including granular tobacco; packaging said
tobacco formulation in a controlled environment.
36. The method of claim 35, wherein said buffer comprises sodium
carbonate and sodium bicarbonate.
37. The method of claim 36, wherein the ratio of sodium carbonate
to sodium bicarbonate is between about 1:20 to 1:99.
38. The method of claim 35, wherein said controlled environment
consists of carbon dioxide.
39. The method of claim 35, wherein said controlled environment
consists essentially of carbon dioxide.
Description
RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S.
application Ser. No. 11/461,628 titled "Smokeless Tobacco" and
filed Aug. 1, 2006, and Ser. No. 11/461,633 titled "Smokeless
Tobacco" and filed Aug. 1, 2006, the entire disclosures of which
are incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention relates to tobacco, and in particular,
to tobacco formulations suitable for use in a smokeless manner, and
to the handling and use of tobacco that is in a smokeless form.
BACKGROUND OF THE INVENTION
[0003] Cigarettes, cigars, little cigars and pipes are popular
smoking articles that employ tobacco in various forms. Smoking
articles are tobacco products that are used by heating or burning
tobacco, and aerosol (e.g., smoke) is inhaled by the smoker.
Representative manners or methods that have been proposed for the
packaging of tobacco products, including cigarettes and cigars, are
set forth in U.S. Pat. No. Des 368,221 to Montague; U.S. Pat. No.
1,886,115 to Muller; U.S. Pat. No. 3,371,775 to Butler; U.S. Pat.
No. 3,967,730 to Driscoll et al.: U.S. Pat. No. 4,852,734 to Allen
et al.; U.S. Pat. No. 5,139,140 to Burrows et al.; U.S. Pat. No.
5,333,729 to Wolfe; 5,542,529 to Hein, III et al.; U.S. Pat. No.
5,938,018 to Keaveney et al. and U.S. Pat. No. 7,014,039 to Henson
et al.; each of which is incorporated herein by reference.
[0004] Tobacco also may be enjoyed in a so-called "smokeless" form.
Particularly popular smokeless tobacco products are employed by
inserting some form of processed tobacco or tobacco-containing
formulation into the mouth of the user.
[0005] Various types of smokeless tobacco products are set forth in
U.S. Pat. No. 1,376,586 to Schwartz; U. S. Pat. No. 4,513,756 to
Pittman et al.; U.S. Pat. No. 4,528,993 to Sensabaugh, Jr. et al.;
U.S. Pat. No. 4,624,269 to Story et al.; U.S. Pat. No. 4,987,907 to
Townsend; U.S. Pat. No. 5,092,352 to Sprinkle, III et al.; U.S.
Pat. No. 5,387,416 to White et al.; and Des. 335,934 to Howard;
U.S. Pat. App. Pub. No. 2005/0244521 to Strickland et al. and
2006/0162732 to Winn et al.; U.S. Pat. App. Pub. Nos. 2006/0191548
to Strickland et al., 2007/0261707 to Winterson et al.,
2007/0062549 to Holton, Jr. et al. and 2007/0186941 to Holton, Jr.
et al.; and PCT Application Pub. No. WO 04/095959 to Arnarp et al.;
PCT Application Pub. No. WO 05/063060 to Atchley et al.; PCT
Application Pub. No. WO 05/004480 to Engstrom; and PCT Application
Pub. No. WO 05/041699 to Quinter et al.; each of which is
incorporated herein by reference. One type of smokeless tobacco
product is referred to as "snuff." Snuff typically is formulated in
"moist" or "dry" forms. Representative types of snuff products,
commonly referred to as "snus," are manufactured in Europe,
particularly in Sweden, by or through companies such as Swedish
Match AB, Fiedler & Lundgren AB, Gustavus AB, Skandinavisk
Tobakskompagni A/S and Rocker Production AB. Snus products
available in the U.S.A. are marketed under the tradenames Camel
Snus Frost, Camel Snus Original and Camel Snus Spice by R.J.
Reynolds Tobacco Company. Representative smokeless tobacco products
also are marketed under the tradenames Oliver Twist by House of
Oliver Twist A/S; Copenhagen, Skoal, SkoalDry, Rooster, Red Seal,
Husky, and Revel by U.S. Smokeless Tobacco Co.; "taboka" by Philip
Morris USA; and Levi Garrett, Peachy, Taylor's Pride, Kodiak,
Hawken Wintergreen, Grizzly, Dental, Kentucky King, and Mammoth
Cave by Conwood Sales Co., L.P.
[0006] Exemplary manners for providing various types of tobacco
products for distribution to consumers have been proposed in U.S.
Pat. No. 3,696,917 to Levi; PCT WO 2004/095959 to Arnarp et al. and
PCT WO 2005/016036 to Bjorkholm; each of which is incorporated
herein by reference. Equipment for packaging tobacco has been
commercially available, and representative equipment has been
available as FPP 210 Pouch Packer from Schur Flexible Benelux.
[0007] Smokeless tobacco products are packaged for distribution,
sale and use in a variety of ways. Chewing tobacco has been
packaged in pouches, foil bags and metal containers. Snus types of
products have been packaged in tins, "pucks" or "pots" that are
manufactured from metal or plastic. In certain circumstances,
smokeless tobacco products are refrigerated prior to sale,
typically for the purpose of prolonging the freshness and moisture
content thereof. For example, smokeless tobacco products,
particularly moist tobacco products, can be refrigerated in order
to avoid or retard absorption of contaminants that provide an
undesirable flavor or odor to the product, avoid or retard the
development discoloration or staining of the product, and to avoid
or retard the activity of biologically active microorganisms. For
example, smokeless tobacco products, and typically moist snuff
types of products, can be refrigerated to retard the effects of
enzymatic and other biological activities, pH changes, oxidation,
and other effects that have a tendency to shorten product
shelf-life or stability. Snus formulations are typically
refrigerated at 38.degree.-40.degree. F. during storage and
shipping. The need to keep such formulations refrigerated increases
the cost of shipping and storing snus.
[0008] It would be desirable to provide efficient and effective
forms of packaging for a smokeless tobacco composition or
formulation. It also would be desirable to provide smokeless
tobacco compositions or formulations, and in particular, processed
smokeless tobacco compositions and formulations.
SUMMARY OF THE INVENTION
[0009] The present invention relates to a smokeless tobacco
product. The product includes a smokeless tobacco composition or
formulation. For example, the smokeless tobacco formulation
includes particles or pieces of tobacco, and may include other
ingredients, such as salts, sweeteners, binders, colorants, pH
adjusters and buffers, fillers, flavoring agents, disintegration
aids, antioxidants, humectants, and preservatives. The moisture
content of the particles of the tobacco may vary. Certain smokeless
tobacco products have the form of tobacco compositions or
formulations that result from casting or otherwise forming a slurry
incorporating tobacco material and other components as a film or
sheet. Certain smokeless tobacco products have the form of tobacco
compositions or formulations that result from pressing, extruding
or otherwise forming a mixture incorporating tobacco material and
other components into a desired shape.
[0010] The tobacco formulation can be contained within a container,
such as a pouch or bag, such as is the type commonly used for the
manufacture of snus types of products (e.g., a sealed, moisture
permeable pouch that is sometimes referred to as a "portion"). A
representative moisture permeable pouch can be composed of a
"fleece" type of material. The tobacco formulation is in turn
contained within a package. The package is sealed tightly, and is
composed of a suitable material, such that the atmospheric
conditions within that sealed package are modified and/or
controlled; that is, the sealed package can provide a good barrier
that inhibits the passage of compositions such as moisture and
oxygen therethrough; in addition, the atmosphere within the sealed
package can be further modified by introducing a selected gaseous
species (e.g., nitrogen, carbon dioxide, argon, or a mixture
thereof) into the package prior to sealing or by drawing a vacuum
therein (vacuum sealing). As such, the atmospheric conditions to
which the tobacco composition is exposed are controlled during
conditions of preparation, packing, storage and handling.
[0011] In one aspect, a smokeless tobacco product is provided. A
water-permeable pouch containing a tobacco formulation and
configured for insertion into the mouth of a user of that product
is provided. The tobacco formulation includes granular tobacco and
a buffer comprised of sodium carbonate and sodium bicarbonate. An
outer packaging material enveloping the pouch is provided and is
sealed so as to allow a controlled environment to be maintained
within.
[0012] In one aspect, a smokeless tobacco product is provided. A
water-permeable pouch containing a tobacco formulation and
configured for insertion into the mouth of a user of that product
is provided. The tobacco formulation includes granular tobacco and
a buffer comprised of at least two buffering elements. An outer
packaging material enveloping the pouch is provided and is sealed
so as to allow a controlled environment to be maintained
within.
[0013] In one aspect, smokeless tobacco product is provided. A
plurality of water-permeable pouches each configured for insertion
into the mouth of a user of that product are provided, each
containing a tobacco formulation including granular tobacco and a
buffer comprised of at least two buffering elements. A hard
container encompasses the water-permeable pouches, and an outer
packaging material envelops the hard container and is sealed to
allow a controlled environment to be maintained within.
[0014] In one aspect, a smokeless tobacco product is provided. A
plurality of water-permeable pouches each configured for insertion
into the mouth of a user of that product are provided, each
containing a tobacco formulation including granular tobacco and a
buffer comprised of at least two buffering elements. A hard
container encompasses the water-permeable pouches, and is sealed to
allow a controlled environment to be maintained within.
[0015] In one aspect, a smokeless tobacco product is provided. A
plurality of water-permeable pouches each configured for insertion
into the mouth of a user of that product are provided, each
containing a tobacco formulation including granular tobacco and a
buffer comprised of at least two buffering elements. An outer
packaging material envelops each of the pouches and is sealed to
allow a controlled environment to be maintained within. A hard
container encompasses the pouches enveloped by the outer packing
material and is tightly sealed so as to allow a controlled
environment to be maintained within.
[0016] In one aspect, a smokeless tobacco product is provided. A
plurality of water-permeable pouches each configured for insertion
into the mouth of a user of that product are provided, each
containing a tobacco formulation including granular tobacco and a
buffer comprised of at least two buffering elements. An outer
packaging material envelops each of the pouches and is sealed to
allow a controlled environment to be maintained within. A hard
container encompasses the pouches enveloped by the outer packing
material. A second outer packaging material envelops the hard
container and is tightly sealed so as to allow a controlled
environment to be maintained within.
[0017] In one aspect a method of maintaining the pH producing
ability of a smokeless tobacco product over a period of time is
provided. A buffer comprising at least two elements is added to a
tobacco formulation that includes granular tobacco and the tobacco
formulation is then packaged in a controlled environment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] In order to provide an understanding of embodiments of the
invention, reference is made to the appended drawings, in which
reference numerals refer to components of described exemplary
embodiments of the invention. The drawings are exemplary only, and
should not be construed as limiting the invention.
[0019] FIG. 1 is an enlarged cross-sectional view of a tobacco
product in the form of a snus type of product individually wrapped
in an outer package.
[0020] FIG. 2 is a cross-sectional view of a tobacco product in the
form of a snus type of product, wherein several snus-type products
are wrapped in an outer package and that outer package is contained
within a generally cylindrical plastic or metal tin.
[0021] FIG. 3 is a cross-sectional view of a tobacco product in the
form of a snus type of product, wherein several snus-type products
are contained within a generally cylindrical plastic or metal tin,
and that tin is wrapped in an outer package.
[0022] FIG. 4 is a cross-sectional view of a tobacco product in the
form of a snus type of product, wherein several snus-type products
are contained within a generally cylindrical plastic or metal tin
possessing a controlled atmosphere.
[0023] FIG. 5 is cross-sectional view of a tobacco product in the
form of a snus type of product, wherein each of several snus-type
products are individually wrapped in an outer package, and are in
turn contained within a generally cylindrical plastic or metal tin
possessing a controlled atmosphere.
[0024] FIG. 6 is a perspective view (partially cut away) of a
plurality of individually packaged snus types of products, each
individual package being connected to another, and an outer
container for containing and dispensing those products.
[0025] FIG. 7 is an enlarged cross-sectional view of a tobacco
product in the form of a snus type of product individually wrapped
in an outer package.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] Referring to FIG. 1, there is shown a first embodiment of a
representative type of smokeless tobacco product 110. The tobacco
product 110 includes a tobacco composition 115 contained in a
sealed, moisture permeable pouch 120, thereby providing a tobacco
portion 122. A representative moisture permeable pouch can be
composed of a fleece type of material that is sealed shut in order
to effectively retain the tobacco composition within the pouch
during normal conditions of handling. The tobacco product 110
possesses a sealed outer package 125 that surrounds and contains
the tobacco portion 122 as a type of tightly sealed pouch. The
representative outer package 125 possesses an upper surface 126 and
a lower surface 127; and the two faces 128, 129 of a "fin seal" are
shown lying essentially parallel to the lower surface of outer
package 125. The outer package 125 is tightly sealed, and is
selected from an appropriate material, such that the atmosphere 130
within that outer package can be controlled. In addition, the
atmosphere 130 within the package can be controlled such that the
atmosphere is composed most predominantly of high purity nitrogen
gas, or other suitable gaseous species such as carbon dioxide. If
desired, the embodiment can be altered in order that the outer
package contains a plurality (e.g., 2, 3 or 4) of individual
tobacco portions. Each of the two ends 131, 132 of the outer
package is tightly sealed (e.g., heat sealed), and if desired,
those ends can have a serrated appearance, or cut to have the
desired visual effect. Preferably, the length of the inner region
of the outer package 125 is at least about 10 percent greater than
the overall length of the tobacco portion 122, the width of the
inner region of the outer package 125 is at least about 10 percent
greater than the overall width of the tobacco portion 122, and the
height of the inner region of the outer package 125 is somewhat
greater than the overall height of the tobacco portion 122. For an
exemplary embodiment, a snus-type of product has a maximum length
of about 20 mm to about 30 mm, a width of about 10 mm to about 15
mm, and a height of about 5 mm to about 8 mm; thus the outer
package 125 would have an overall length of at least about 30 mm, a
width of at least about 30 mm, and a height of at least about 5 mm
to about 8 mm; wherein the two end seals 131, 132 of the outer
package 125 each extend about 5 mm along the width of the outer
package 125, and the "fin seal" has a width of about 10 mm. In use,
the outer package 125 is opened by the consumer, the tobacco
portion 122 is removed from the outer package, and the tobacco
portion is enjoyed by the consumer.
[0027] Referring to FIG. 2, there is shown a second embodiment of a
representative smokeless tobacco product 110. The tobacco product
110 includes several tobacco compositions 115, 140, 141 each
contained in a respective sealed, moisture permeable pouch 120,
145, 146. The tobacco product 110 possesses a sealed outer package
155 that surrounds and contains all of those individual tobacco
portions 125, 157, 158. The number of tobacco portions within the
outer package can vary, and can be a number such as 10, 12, 15, 20,
25 or 30. The outer package 155 is tightly sealed, and for the
representative embodiment shown, the outer package 155 possesses a
three-sided type of packaging configuration (i.e., the packaging
material used to manufacture the outer package is sealed on three
sides). The outer package 155 is selected from an appropriate
material, such that the atmosphere 160 within that outer package
can be controlled. For example, the atmosphere 160 within the
package can be controlled such that the atmosphere is composed of
high purity nitrogen gas, or other suitable gaseous species such as
carbon dioxide. The outer package 155 is contained within a hard
container 165, such as a plastic or metal tin having a lower
portion 168 and a corresponding or coordinating upper portion 170.
A representative hard container 165 is the short, rounded edge,
generally cylindrical container traditionally used for the
marketing of snus types of products. See, for example, the types of
representative snuff-box types of designs set forth in PCT WO
2005/016036 to Bjorkholm. Other types of containers that can be
suitably modified are plastic or metal type containers set forth in
U.S. Pat. No. 7,014,039 to Henson et al. See, also, the types of
hard containers used for the commercial distribution of Camel Snus
by R.J. Reynolds Tobacco Company; Revel Mint Tobacco Packs type of
smokeless tobacco product by U.S. Smokeless Tobacco Corporation;
SkoalDry by U.S. Smokeless Tobacco Co. and "taboka" by Philip
Morris USA. If desired, the type of container used for the "taboka"
product can be adapted to possess a slidable lid (e.g., one that
slides generally parallel to the longitudinal axis of the
container) in order that the container can be opened and closed. If
desired, the container can have an accordion or bellows type of
design, such that the container can be extended open for filling
with smokeless tobacco product during production, and then
contracted after filling of the container is complete. If desired,
containers can be equipped with suitable seals or grommets, in
order that when an opened container is re-shut, a good seal is
provided.
[0028] In use, the hard container is opened, the outer package is
opened, a tobacco portion is removed therefrom, and the tobacco
portion is enjoyed by the consumer. The hard container can be
manually resealed, and additional tobacco portions can be removed
from that container by the consumer as desired.
[0029] Referring to FIG. 3, there is shown a third embodiment of a
representative smokeless tobacco product 110. The tobacco product
110 includes several tobacco compositions 115, 140, 141 each
contained in a respective sealed, moisture permeable pouch 120,
145, 146. Those individual pouch sealed tobacco portions 156, 157,
158 are themselves contained within a hard container 165, such as a
plastic or metal tin having a lower portion 168 and a corresponding
or coordinating upper portion 170. The number of tobacco portions
within the hard container can vary, and can be a number such as 10,
12, 15, 20, 25 or 30. A representative hard container 165 is the
short, rounded edge, generally cylindrical container traditionally
used for the marketing of snus types of products. The hard
container 165 is in turn packaged within a sealed outer package
180. The representative outer package 180 shown as a representative
embodiment has a "lap seal" type of sealing mechanism, and as such,
possesses an upper surface 182, a lower surface 183, and an overlap
seal 184 located on the bottom face of the outer package. The outer
package 180 is tightly sealed at each end 185, 186, and is
constructed from an appropriate material, such that the atmosphere
160 within that outer package, and within the hard container 165,
is controlled. For example, the atmosphere 160 within the package
can be controlled such that the atmosphere is composed of high
purity nitrogen gas, or other suitable gaseous species such as
carbon dioxide. In use, the outer package 180 is opened, the hard
container 165 is opened, and individual tobacco portions are
removed as desired from the hard container.
[0030] Referring to FIG. 4, there is shown a fourth embodiment of a
representative smokeless tobacco product 110. The tobacco product
110 includes several tobacco compositions 115, 140, 141 each
contained in a sealed, moisture permeable pouch 120, 145, 146,
respectively. Those individual tobacco portions 156, 157, 158 are
contained within a hard container 165, such as a plastic or metal
tin having a lower portion 170 and a corresponding or coordinating
upper portion 168. A representative hard container 165 is the
short, rounded edge, generally cylindrical container traditionally
used for the marketing of snus types of products. The hard
container 165 is in turn tightly sealed, and can possess an
optional ring or band of a sealing material 195 that circumscribes
the hard container in the area of the seal between lower and upper
portions 168, 170. As such, conditions are provided so that the
atmosphere 160 within the hard container 165, can be controlled
(e.g., the atmosphere may be composed of high purity nitrogen gas,
or other suitable gaseous species such as carbon dioxide). In use,
the ring or band of sealing material 195 is broken, the hard
container is opened, and individual tobacco portions are removed as
desired from the hard container.
[0031] Referring to FIG. 5, there is shown a fifth embodiment of a
representative smokeless tobacco product 110. The tobacco product
110 includes several tobacco compositions 115, 140, 141 each
contained in a sealed, moisture permeable pouch 120, 145, 146,
respectively. Each individual tobacco portion 156, 157, 158
possesses a sealed outer package 125, 211, 212 that surrounds and
contains each respective tobacco portion. Each outer package 125,
211, 212 is tightly sealed, and is selected from an appropriate
material, such that the atmosphere 130, 221, 222 within each
respective outer package can be controlled. For example, the
atmosphere 130, 221, 222 within each respective outer package can
be controlled such that the atmosphere is composed of high purity
nitrogen gas, or other suitable gaseous species such as carbon
dioxide. If desired, this embodiment can be altered to provide that
each outer package 125, 211, 212 contains a plurality (e.g., 2, 3
or 4) of individual tobacco portions 156, 157, 158. The packaged
individual tobacco portions 156, 157, 158 are in turn contained
within a hard container 165, such as a plastic or metal tin having
a lower portion 170 and a corresponding or coordinating upper
portion 168. A representative hard container 165 can be the short,
rounded edge, generally cylindrical container traditionally used
for the marketing of snus types of products. The hard container 165
is in turn tightly sealed, and can possess an optional ring or band
of a sealing material 195 that circumscribes the hard container in
the area of the seal between lower and upper portions 168, 170. As
such, conditions are provided so that the atmosphere 160 within
that hard container 165, is controlled (e.g., the atmosphere is
composed of high purity nitrogen gas, or other suitable gaseous
species such as carbon dioxide). Alternatively, the hard container
165 can be optionally packaged in a sealed outer package 180, such
as in the manner previously set forth with reference to FIG. 3
(e.g., so that the conditions within that outer package, and hence
within the hard container, are controlled). In either case, the
modified or controlled atmosphere 160 within hard container 165 can
be the same or different than the modified or controlled
atmospheres 130, 221, 222 of each of the outer packages 125, 211,
212 of the individually wrapped tobacco portions 156, 157, 158
(e.g., the hard container can be packaged within an outer package
that provides a type of vacuum seal and the individually wrapped
tobacco portions can be wrapped under controlled atmosphere; or the
individually wrapped tobacco portions can be packaged within outer
packages that provide a type of vacuum seal and the outer packaged
can be wrapped so as to provide internal conditions of controlled
atmosphere). In use, the outer package is broken, the hard
container is opened, a packaged individual tobacco portion is
removed from the hard container, and that packaged portion is
opened so that the tobacco portion can be enjoyed by the
consumer.
[0032] Referring to FIG. 6, there is shown a sixth embodiment of a
representative smokeless tobacco product 110. The tobacco product
110 may include several tobacco compositions (not shown) each
contained in a sealed, moisture permeable pouch (not shown). The
tobacco compositions and tobacco portions are of the type
previously described with reference to FIG. 5. Each individual
tobacco portion possesses a sealed outer package 125, 211, 212 that
surrounds and contains each respective tobacco portion. Each outer
package 125, 211, 212 is tightly sealed, and is selected from an
appropriate material, such that the atmosphere (not shown) within
each respective outer package can be controlled (e.g., vacuum
sealed). In addition, the atmosphere within each respective package
can be controlled such that the atmosphere is composed of high
purity nitrogen gas, or other suitable gaseous species such as
carbon dioxide. If desired, this embodiment can be altered so that
each outer package 125, 211, 212 contains a plurality (e.g., 2, 3
or 4) of individual tobacco portions. The packaged individual
tobacco portions within the outer packages 125, 211, 212 are in
turn connected to one another in an end-to-end relationship. That
is, the individual outer packages 125, 211, 212 each are "fin
sealed" along respective sealing regions 270, 271, 272. The fin
seal extends longitudinally along the length of each outer package.
For the embodiment shown, each fin sealed region 270, 271, 272 may
possess 5 "jaw lines." At each end of outer package 125, and
preferably generally perpendicular to the longitudinally extending
fin seal, are end seals 131, 132. In addition, there are comparable
end seals for each of the other outer packages. For the embodiment
shown, the end seal of each outer package may possess 3 "jaw
lines." Between adjacent end seals of each outer package is a line
of perforations 305, 306, 307, such that each individual package
can be separated from the next. A desired number of the connected
outer packages (e.g., 10, 12, 15, 20, 25 or 30) are rolled or wound
in a generally spiral manner (e.g., as in a manner generally akin
to a spool or roll of postage stamps). The resulting wound series
of connected outer packages then is positioned within a suitable
container 315. One end of the spooled series of outer packages
extends through an opening 320 in the side face of the container
315. As such, the container can hold the spooled product, as well
as provide a manner or method for dispensing product therefrom. As
such, there is provided a dispenser for an essentially continual
strip of smokeless tobacco product (e.g., individual portions of
smokeless tobacco composition that are connected together but are
separable from one another about individual tearable lines of
perforation).
[0033] For the embodiment shown in FIG. 6, the individual packages
are connected in an "end-to-end" type of arrangement. If desired,
the configuration by which the individual packages can be connected
can be altered. For example, rather than sealing the individual
outer packages at each end of the length of a smokeless product,
the smokeless product can be rotated 90.degree., and the end seals
of the outer package can be parallel to the length of the smokeless
product. As such, individual outer packages for smokeless product
can be aligned in a "side-by-side" type of arrangement.
[0034] For the type of embodiment shown in FIG. 6, individual
packages that are connected to one another in either an
"end-to-end" or "side-by-side" type of arrangement can be
incorporated into other types of containers for commercial
distribution. For example, a predetermined number (e.g., 4, 5 or
10) of connected but divisible individual outer packages can be
incorporated within a package of cigarettes. When incorporated
within the cigarette package, it is particularly desirable to have
the smokeless product sealed in a controlled atmosphere in order
that flavors and aromas do not migrate as between the cigarettes
and the smokeless product. In this way product integrity is
preserved for each of the jointly packaged products. In one
embodiment, cigarettes can be packaged in a so-called "hard pack",
having a lid that extends upward beyond the ends of the cigarettes
that are contained therein, and a strip of connected individual
packages can be positioned within the inner, upper portion of that
lid. Exemplary hard pack designs are set forth in U.S. Pat. Nos.
4,852,734 to Allen et al.; U.S. Pat. No. 5,139,140 to Burrows et
al. and U.S. Pat. No. 5,938,018 to Keaveney et al. (For example, a
hard pack designed for containing cigarettes having lengths of
about 99 mm in a 7-6-7 configuration can be filled with comparable
cigarettes having lengths of about 85 mm, and several packaged
smokeless tobacco portions can be contained within the inner top
region of the movable top lid). Alternatively, several packaged
smokeless tobacco portions can be included with a cigarette package
by containing those packaged smokeless portions within the
polypropylene overwrap that covers the outer regions of the
cigarette package. Similarly, packaged smokeless tobacco portions
can be connected to a cigarette package by adhesive or by fastening
as an onsert.
[0035] Alternative types of packaging that could be used to contain
individual smokeless tobacco portions are set forth in U.S. Pat.
Nos. 7,216,776 and 6,863,175 to Gelardi and U.S. Pat No. 6,913,149
to Gelardi et al. These types of packaging could dispense pill-type
smokeless tobacco portions and have the added benefit of being
child-proof. Such types of packaging would need to be suitably
modified to maintain a controlled atmosphere in accordance with the
present invention.
[0036] Referring to FIG. 7, there is shown yet another embodiment
of a representative type of smokeless tobacco product 110. The
tobacco product 110 includes a tobacco composition 115 contained in
a sealed, moisture permeable pouch 120, thereby providing a tobacco
portion 122. The tobacco product 110 possesses a sealed outer
package 125 that surrounds and contains the tobacco portion 122 in
a type of tightly sealed manner. The representative outer package
125 possesses an upper surface 126 and a lower surface 127. The
lower surface 127 is suitably adapted so as to possess a so-called
"blister pack" type of format and configuration. As such, the lower
surface can have the general shape of a "bubble" having some degree
of structural integrity, and hence can be formed to have a
generally hemispherical shape, or other desired shape. The outer
package 125 is tightly sealed, and is selected from an appropriate
material, such that the atmosphere 130 within that outer package is
controlled. If desired, the embodiment can be altered in order that
the outer package contains a plurality (e.g., 2, 3 or 4) of
individual tobacco portions. An edge region 426 about which outer
package is tightly sealed (e.g., heat sealed) preferably extends
around the bubble region of the blister pack. The edge region can
form a shape that is rectangular, square, triangular, hexagonal,
circular, or other desired shape. If desired, the edge region 426
of each outer package can have a serrated appearance; can be
perforated so as to be connected in a strip or matrix to other
outer packages, or can be cut to have the desired visual effect.
Preferably, the length of the inner region of the outer package is
at least about 10 percent greater than the overall length of the
tobacco portion, the width of the inner region of the outer package
is at least about 10 percent greater than the overall width of the
tobacco portion, and the height of the inner region of the outer
package is somewhat greater than the overall height of the tobacco
portion. For an exemplary embodiment, a snus-type of product has a
maximum length of about 30 mm, a width of about 10 mm to about 12
mm, and a height of about 5 mm to about 6 mm; and the outer package
has a length of about 40 mm, a width of about 15 mm and a height of
15 mm; and the end seals of outer package extend around the
"bubble" portion at a width of about 5 mm to about 10 mm. Tobacco
product so packaged can be employed in the general manner set forth
previously with reference to FIGS. 1, 2, 5 and 6.
[0037] Furthermore, while the figures of the present application
illustrate a snus product, other types of products such as those
set forth in U.S. Pat. Pub. No. 2006/0191548 to Strickland, et al.
and U.S. application Ser. No. 11/781,604 to Dube, et al., the
entire disclosures of which are incorporated herein by reference,
could also be used in accordance with the present invention.
[0038] Tobaccos used for the manufacture of tobacco products
pursuant to the embodiments herein may vary. The tobaccos may
include types of tobaccos such as flue-cured tobacco, burley
tobacco, Oriental tobacco, Maryland tobacco, dark tobacco,
dark-fired tobacco and Rustica tobaccos, as well as other rare or
specialty tobaccos. Descriptions of various types of tobaccos,
growing practices, harvesting practices and curing practices are
set forth in Tobacco Production, Chemistry and Technology, Davis et
al. (Eds.) (1999), which is incorporated herein by reference. See,
also, the types of tobaccos that are set forth in U.S. Pat. No.
4,660,577 to Sensabaugh, Jr. et al.; U.S. Pat. No. 5,387,416 to
White et al.; U.S. Pat. No. 6,730,832 to Dominguez et al.; and U.S.
Pat No. 7,025,066 to Lawson et al.; U.S. Pat. App. Pub. Nos.
2007/0062549 to Holton, Jr. et al. and 2007/0186941 to Holton, Jr.
et al.; and U.S. application Ser. No. 11/781,666 to Humphrey, each
of which is incorporated herein by reference. Most preferably, the
tobacco materials are those that have been appropriately cured and
aged. Especially preferred techniques and conditions for curing
flue-cured tobacco are set forth in Nestor et al., Beitrage
Tabakforsch. Int., 20 (2003) 467-475 and U.S. Pat. No. 6,895,974 to
Peele, which are incorporated herein by reference. Representative
techniques and conditions for air curing tobacco are set forth in
Roton et al., Beitrage Tabakforsch. Int., 21 (2005) 305-320 and
Staaf et al., Beitrage Tabakforsch. Int., 21 (2005) 321-330, which
are incorporated herein by reference.
[0039] Tobacco such as that used in snus marketed under the trade
names Camel Snus Frost, Camel Snus Original and Camel Snus Spice by
R.J. Reynolds Tobacco Company can also be used. Typically, types of
tobacco having 1% or less than 1% nicotine content are used in
these formulations and the collective nicotine content of the
tobacco blend is near about 2% the dry weight of the tobacco, often
less than 1.5% of the dry weight of the tobacco, frequently
0.5%-1.25% the dry weight of tobacco and often 1% or less of the
dry weight of the tobacco.
[0040] Tobacco having low levels of tobacco specific nitrosamines,
such as those disclosed in U.S. Pat. No. 6,834,654 to Williams,
which is herein incorporated by reference, can also be utilized
with the present invention.
[0041] The tobacco used for the manufacture of the tobacco product
preferably is provided in a shredded, ground, granulated, fine
particulate or powder form. The tobacco used for the manufacture of
the tobacco product also can be processed, blended, formulated,
combined and mixed with other materials or ingredients. For
example, the tobacco composition can incorporate salts, sweeteners,
binders, colorants, pH adjusters or buffers, fillers, flavoring
agents, disintegration aids, antioxidants, humectants, and
preservatives. See, for example, those representative components,
combination of components, relative amounts of those components and
ingredients relative to tobacco, and manners and methods for
employing those components, set forth in U.S. Pat. App. Pub. Nos.
2007/0062549 to Holton, Jr. et al. and 2007/0186941 to Holton, Jr.
et al., each of which is incorporated herein by reference. For
example, the tobacco product can have the form of a pouch
containing a tobacco composition, and a flavored strip or film; the
form of a pouch containing a tobacco composition, and a flavored
strip or film incorporating finely divided granules of tobacco
and/or tobacco extract (e.g., components of a spray dried aqueous
extract of tobacco); or the form of a highly processed dissolvable
film incorporating finely divided granules of tobacco and/or
tobacco extract. Typically, for certain embodiments, the amount of
tobacco material within a portion of an individual portion of a
smokeless tobacco can be, on a dry weight basis, at least about 30
mg, often at least about 40 mg, and frequently at least about 45
mg; while that amount typically is less than about 200 mg, often
less than about 150 mg, and frequently less than about 100 mg. The
tobacco material can have the form of processed tobacco parts or
pieces, cured and aged tobacco in essentially natural lamina or
stem form, a tobacco extract, extracted tobacco pulp (e.g., using
water as a solvent), or a mixture of the foregoing (e.g., a mixture
that combines extracted tobacco pulp with granulated cured and aged
natural tobacco lamina).
[0042] A blend of different types of tobacco can also be used. For
example, a mixture can contain a blend of 75% flue cured tobacco
and 25% other types of tobacco such as burley, Turkish, dark air
cured or rare specialty tobaccos. Or, the blend could be 100% of
one type of tobacco, such as flue cured.
[0043] The moisture content of the tobacco formulation prior to use
by a consumer of the formulation may vary. Typically, the moisture
content of the tobacco formulation, as present within the pouch
prior to insertion into the mouth of the user, is less than about
55 weight percent, generally is less than about 50 weight percent,
and often is less than about 45 weight percent. Certain types of
tobacco formulations have moisture contents, prior to use, of less
than about 15 weight percent, frequently less than about 10 weight
percent, and often less than about 5 weight percent. For certain
tobacco products, such as those incorporating snus-types of tobacco
compositions, the moisture content may exceed 20 weight percent,
and often may exceed 30 weight percent. For example, a
representative snus-type product may possess a tobacco composition
exhibiting a moisture content of about 25 weight percent to about
50 weight percent, preferably about 30 weight percent to about 40
weight percent.
[0044] The manner by which the moisture content of the formulation
is controlled may vary. For example the formulation may be
subjected to thermal or convection heating. As a specific example,
the formulation may be oven-dried, in warmed air at temperatures of
about 40.degree. C. to about 95.degree. C., with a preferred
temperature range of about 60.degree. C. to about 80.degree. C. for
a length of time appropriate to attain the desired moisture
content. Alternatively, tobacco formulations may be moistened using
casing drums, conditioning cylinders or drums, liquid spray
apparatus, ribbon blenders, mixers available as FKM130, FKM600,
FKM1200, FKM2000 and FKM3000 from Littleford Day, Inc., Plough
Share types of mixer cylinders, and the like. Most preferably,
moist tobacco formulations, such as the types of tobacco
formulations employed within snus types of products, are subjected
to pasteurization or fermentation. Techniques for pasteurizing or
fermenting snus types of tobacco products will be apparent to those
skilled in the art of snus product design and manufacture.
[0045] The acid or base content of a tobacco formulation gives it
the ability to produce a pH. In the present application, "the pH of
the tobacco" refers to the ability of the tobacco to produce a
certain pH level. The pH of the tobacco formulation can vary.
Typically, the pH of that formulation is at least about 6.5, and
preferably at least about 7.5. Typically, the pH of that
formulation will not exceed about 9, and often will not exceed
about 8.5. A representative tobacco formulation exhibits a pH of
about 6.8 to about 8.2. A representative technique for determining
the pH of a tobacco formulation involves dispersing 2 g of that
formulation in 10 ml of high performance liquid chromatography
water, and measuring the pH of the resulting suspension/solution
(e.g., with a pH meter).
[0046] If desired, a buffer can be added to the snus formulation to
help maintain the pH levels during shipping and storage without the
need for refrigeration. Sodium carbonate alone has been used as a
buffer in the past. It is typically added to the snus formulation
in an amount that is about 3-10% of the dry weight of the snus
formulation. It has been discovered that a new combination of
elements provides improved buffering characteristics over time, and
when combined with the modified atmosphere packaging described
later, the combination nearly eliminates any significant change in
pH in snus formulations over time without the need for traditional
refrigeration. The preferred buffer formulation is sodium carbonate
and sodium bicarbonate at a ratio of between about 1:75 and about
1:80, although ratios from 1:20 up to 1:99 are also effective.
[0047] If such a buffer is desired, water is added to a snus
tobacco blend to bring the formulation to about 45% moisture
content. Salt is added at 1.5% of the dry weight of the snus
formulation. The mixture is pasteurized at 212.degree. F.
(100.degree. C.) for one hour and then dried down to about 20-25%
moisture content. The mixture is then brought up to 55% moisture
content in a solution of the buffer made up of sodium carbonate and
sodium bicarbonate in the ratios detailed above. The buffer is
added to the snus formulation in an amount that is about 7-15% of
the dry weight of the snus formulation. During this period, the pH
goes from about 9-9.5 to 7.8-8.
[0048] Other buffer recipes are also contemplated, although they
may not exhibit the same synergy that the sodium carbonate/sodium
bicarbonate buffer does in conjunction with carbon dioxide modified
atmosphere packaging. Other buffer recipes include sodium carbonate
and ammonium bicarbonate at a ratio of 2:3, potassium hydroxide and
sodium bicarbonate at a ratio of 1:75, sodium hydroxide and
potassium bicarbonate at a ratio of 1:75, and potassium hydroxide,
sodium carbonate and sodium bicarbonate at a ratio of 2:5:3. Each
of these buffer recipes is added to the snus formulation as
described above, in an amount that is about 7-15% of the dry weight
of the snus formulation.
[0049] If desired, prior to preparation of the tobacco formulation,
the tobacco parts or pieces may be irradiated, or those parts and
pieces may be pasteurized, or otherwise subjected to controlled
heat treatment. Additionally, if desired, after preparation of all
or a portion of the formulation, the component materials may be
irradiated, or those component materials may be pasteurized, or
otherwise subjected to controlled heat treatment. For example, a
formulation may be prepared, followed by irradiation or
pasteurization, and then flavoring ingredient(s) may be applied to
the formulation. Alternatively, the tobacco formulation can be
irradiated or pasteurized after the tobacco formulation has been
incorporated within a moisture-permeable packet or pouch (e.g., so
as to provide individual containers of snus-type smokeless tobacco
product.
[0050] The composition/construction of a moisture-permeable packet
or pouch that acts as a snus-type container for use of the tobacco
formulation can vary. Suitable packets, pouches or containers of
the type used for the manufacture of smokeless tobacco products are
available under the tradenames "taboka," CatchDry, Ettan, General,
Granit, Goteborgs Rape, Grovsnus White, Metropol Kaktus, Mocca
Anis, Mocca Mint, Mocca Wintergreen, Kicks, Probe, Prince, Skruf,
TreAnkrare, Camel Snus Original, Camel Snus Frost and Camel Snus
Spice. The tobacco formulation may be contained in pouches and
packaged, in a manner and using the types of components used for
the manufacture of conventional snus types of products. The pouch
or fleece provides a liquid-permeable container of a type that may
be considered to be similar in character to the mesh-like type of
material that is used for the construction of a tea bag. Components
of the loosely arranged, granular tobacco formulation readily
diffuse through the pouch and into the mouth of the user.
[0051] Descriptions of various components of snus types of products
and components thereof also are set forth in U.S. Pat. App. Pub.
No. 2004/0118422 to Lundin et al., which is incorporated herein by
reference. See, also, for example, U.S. Pat. No. 4,607,479 to
Linden; U.S. Pat. No. 4,631,899 to Nielsen; U.S. Pat. No. 5,346,734
to Wydick et al.; and U.S. Pat. No. 6,162,516 to Derr, and U.S.
Pat. App. Pub. No. 2005/0061339 to Hansson et al.; each of which is
incorporated herein by reference. See, also, the representative
types of pouches, and pouch material or fleece, set forth in U.S.
Pat. No. 5,167,244 to Kjerstad, which is incorporated herein by
reference. Snus types of products can be manufactured using
equipment such as that available as SB 51-1/T, SBL 50 and SB 53-2/T
from Merz Verpackungmaschinen GmBH. Snus pouches can be provided as
individual pouches, or a plurality of pouches (e.g., 2, 4, 5, 10,
12, 15, 20, 25 or 30 pouches) can connected or linked together
(e.g., in an end-to-end manner) such that a single pouch or
individual portion can be readily removed for use from a one-piece
strand or matrix of pouches.
[0052] Although the tobacco composition most preferably is provided
in a form that is characteristic of a snus type of product, the
tobacco composition also can have the form of loose moist snuff,
loose dry snuff, chewing tobacco, pelletized tobacco pieces,
extruded tobacco strips or pieces, finely divided ground powders,
finely divided or milled agglomerates of powdered pieces and
components, flake-like pieces (e.g., that can be formed by
agglomerating tobacco formulation components in a fluidized bed),
molded processed tobacco pieces, pieces of tobacco-containing gum,
products incorporating mixtures of edible material combined with
tobacco pieces and/or tobacco extract, products incorporating
tobacco (e.g., in the form of tobacco extract) carried by a solid
inedible substrate, and the like. For example, the tobacco
composition can have the form of compressed tobacco pellets,
multi-layered extruded pieces, extruded or formed strands, rods or
sticks (for example, a strand, rod or stick having a length of
about 3-7 centimeters, preferably about 4-6 centimeters, and a
diameter of about 1-5 millimeters, preferably about 2-4
millimeters), compositions having one type of tobacco formulation
surrounded by a different type of tobacco formulation, rolls of
tape-like films, readily water-dissolvable or water-dispersible
films or strips, or capsule-like materials possessing an outer
shell (e.g., a pliable or hard outer shell that can be clear,
colorless, translucent or highly colored in nature) and an inner
region possessing tobacco or tobacco flavor (e.g., a Newtoniam
fluid or a thixotroic fluid incorporating tobacco of some
form).
[0053] Processed tobacco compositions, such as compressed tobacco
pellets can be produced by compacting granulated tobacco and
associated formulation components, compacting those components in
the form of a pellet, and optionally coating each pellet with an
overcoat material. Exemplary granulation devices are available as
the FL-M Series granulator equipment (e.g., FL-M-3) from Vector
Corporation and as WP 120V and WP 200VN from Alexanderwerk, Inc.
Exemplary compaction devices, such as compaction presses, are
available as Colton 2216 and Colton 2247 from Vector Corporation
and as 1200i, 22001, 3200, 2090, 3090 and 4090 from Fette
Compacting. Devices for providing outer coating layers to compacted
palletized tobacco formulations are available as CompuLab 24,
CompuLab 36, Accela-Cota 48 and Accela-Coata 60 from Thomas
Engineering.
[0054] Processed tobacco compositions, such as multi-layered
tobacco pellets, can be manufactured using a wide variety of
extrusion techniques. For example, multi-layered tobacco pellets
can be manufactured using co-extrusion techniques (e.g., using a
twin screw extruder). In such a situation, successive wet or dry
components or component mixtures can be placed within separate
extrusion hoppers. Steam, gases (e.g., ammonia, air, carbon
dioxide, and the like), and humectants (e.g., glycerin or propylene
glycol) can be injected into the extruder barrel as each dry mix is
propelled, plasticized, and cooked. As such, the various components
are processed so as to be very well mixed, and hence, come in
complete contact with each other. For example, the contact of
components is such that individual components can be well embedded
in the extrusion matrix or extrudate. See, for example, U.S. Pat.
No. 4,821,749 to Toft et al., which is incorporated herein by
reference.
[0055] Certain tobacco compositions can incorporate tobacco as the
major component thereof. Preferably, those compositions do not, to
any substantial degree, leave any residue in the mouth of the user
thereof. Preferably, those compositions do not provide a the user's
mouth with slick or slimy sensation (e.g., due to overly high
levels of binding agents). Tobacco materials, during processing,
can be treated with pH adjusters or other suitable agents, so that
natural pectins within the tobacco material can be released.
Release of natural tobacco pectin can act to reduce the amount of
additional gums/hydrocolloids, cellulose-derived, or starch-based
binders needed to aid in desired sheet or film tensile strength
qualities. For example, to release pectin, fine tobacco powder is
cooked in an alkaline pH adjusted solution at elevated temperatures
relative to ambient. Such treatment also can provide desirable
sensory attributes to the tobacco material. See, for example, U.S.
Pat. No. 5,099,864 to Young et al.; U.S. Pat. No. 5,339,838 to
Young et al. and U.S. Pat. No. 5,501,237 to Young et al.; which are
incorporated herein by reference.
[0056] One representative type of individual portion tobacco
product possesses an outer shell and an inner region in the form of
a tobacco formulation. A representative outer shell can be provided
by providing a liquid mixture of alginates (e.g., sodium alginates
available as Kelvis, Kelgin and Mannucol from International
Specialty Products Corp.), rice starch, sucralose, glycerin and
flavoring agent (e.g., mint flavor) in water so as to provide a
liquid mix exhibiting a Brookfield viscosity at 25.degree. C. of
about 20,000 to about 25,000 centipoise. That viscous mixture can
be used to form a sheet that can be formed into an outer layer
(e.g., using a Villaware Imperia Pasta Machine, Dough Roller 150
equipped with a Villaware Ravioli Attachment for Imperia 150-25,
each of which is available through Imperia Trading Company) or
semi-circular shells that can be combined (e.g., by exposure to
heat) to form an outer layer. Typically, such a viscous mixture can
be suitably dried by heating at about 60.degree. C. for about 1
hour. Inside that outer shell can be incorporated a wide variety of
tobacco formulations. One representative tobacco formulation used
as the inner region is a dry or moist mixture of granulated or
milled tobacco material that can be mixed with other ingredients,
such as flavoring agents, humectants, emulsifiers, fillers, pH
adjusters, dispersion aids, and the like. One representative
tobacco formulation has the form of a fluid (e.g., the form of a
weak gel or soft gel). That tobacco formulation can be provided by
mixing granulated or milled tobacco material, kappa-carageenan,
Kelvis-type sodium alginate, propylene glycol, polysobate 60, and
flavoring agent (e.g., menthol and cinnamon) in water, such that
the moisture content of the formulation is about 40 to about 50
weight percent. One representative tobacco formulation has the form
of a fluid. That tobacco formulation can be provided by mixing
granulated or milled tobacco material, glycerin, glycerol stearate,
propylene glycol, kappa-carageenan, carboxymethycellulose available
as Ticalose 1500 from TIC Gums and micro-crystalline cellulose
(e.g., Ticacel HV from TIC Gums) in water, such that the moisture
content of the formulation is about 60 to about 70 weight
percent.
[0057] The amount of tobacco formulation incorporated within each
sealed outer package can vary. In one aspect, loose tobacco
composition can be incorporated into an outer package, the package
is sealed, and that loose tobacco can be used as loose snuff or
chewing tobacco when the outer package is opened. In another, but
preferred, aspect, tobacco composition contained within a snus-type
pouch or packet is incorporated within the outer package, the
package is sealed, and the snus-type product can be used when the
outer package is opened. Typically, the amount of tobacco
formulation within each individual portion (e.g., within each
snus-type pouch) is such that there is at least about 50 mg, often
at least about 150 mg, and frequently at least about 250 mg, of dry
weigh tobacco; and less than about 700 mg, often less than about
500 mg, and frequently less than about 300 mg, of dry weight
tobacco. For example, snus-type smokeless tobacco products can have
the form of so-called "portion snus."
[0058] One exemplary snus-type product possesses about 1 g of a
tobacco formulation having a moisture content of about 35 weight
percent; which tobacco formulation is contained in a sealed fleece
pouch having an overall length of about 30 mm, a width of about 16
mm, and a height of about 5 mm, wherein the length of the
compartment area of that pouch is about 26 mm due to a seal of
about 2 mm width at each end of that pouch. Another exemplary
snus-type product possesses about 0.5 g of a tobacco formulation
having a moisture content of about 35 weight percent; which tobacco
formulation is contained in a sealed fleece pouch having an overall
length of about 26 mm, a width of about 12 mm, and a height of
about 5 mm, wherein the length of the compartment area of that
pouch is about 22 mm due to a seal of about 2 mm width at each end
of that pouch.
[0059] The outer packaging material useful in accordance with the
present invention can vary. Typically, the selection of the
packaging material is dependent upon factors such as aesthetics,
comfort of handling, desired barrier properties (e.g., so as to
provide protection from exposure to oxygen or radiation, or so as
to provide protection from loss of moisture), or the like. The
packaging material most preferably has the form of a film, such as
a laminated film (e.g., a co-extruded laminated film). The number
of layers present with a laminated packaging material can vary; and
can be at least about 3 layers, and often at least about 4 layers;
while typically, the number of layers does not exceed about 10
layers, and often does not exceed about 8 layers. Overall
thicknesses of exemplary packaging materials typically are at least
about 0.0025 inch, often at least about 0.003 inch; while
typically, the thickness of the packaging materials typically is
less than about 0.006 inch, and often less than about 0.005 inch.
Representative materials that can be used to provide components or
layers of film materials or laminated films can include polyvinyl
chloride, ethylene vinyl acetate co-polymer, oriented
polypropylene, linear low density polyethylene, polyvinylidene
dichloride, polyester terephalate, ethylene methacrylic acid
co-polymer, metallacene linear low density polyethylene, and the
like. Exemplary packaging materials can be plastic/metal films,
plastic/metal films that are paper coated, plastic laminate films,
or the like. Such types of materials can be manufactured from
materials that make them essentially impervious to oxygen and/or
moisture, can be sealed to provide a seal with good integrity, and
can provide an outer package that retains or maintains its
impervious nature or character over time. Suitable materials are of
the type that have been employed as packaging materials for the
controlled atmosphere or vacuum packaging of food and
pharmaceutical types of products.
[0060] Exemplary other materials useful for providing packaging
materials of the present invention preferably include flexible-type
plastic materials. See, for example, those polymeric materials,
sealants, adhesives, and the like, set forth in US Pat. Pub. No.
2004/0043165 to Van Hulle et al.; which is incorporated herein by
reference. For packaging materials that are used for the purpose of
preventing contamination of the tobacco composition by oxygen, it
is desirable to incorporate an effective amount of suitable
reducing agent into the material that provides the inner surface of
the packaging material.
[0061] One exemplary laminated film possesses four layers; the top
or outer layer being composed of a layer of polyester terephalate
(PET) having a thickness of about 0.00048 inch, a thin layer of
adhesive (e.g., a polyurethane-type adhesive available under the
tradename Tycel from the Liofol Company), a metal film (e.g.,
aluminum) having a thickness of about 0.00035 inch, and a bottom
layer of an ethylene methacrylic acid containing composition
available under the tradename Surlyn from E.I. DuPont de Nemours
& Company and having a thickness of about 0.002 inch. If
desired, the side of the PET adjacent the adhesive can be printed
with product information using a suitable ink. Another exemplary
laminated film possesses three layers; the top or outer layer being
composed of a layer of PET having a thickness of about 0.00048
inch, a thin layer of adhesive (e.g., an adhesive available as
Tycel), and a bottom layer of a composition available as Surlyn and
having a thickness of about 0.002 inch. Another exemplary laminated
film possesses four layers; the top or outer layer being composed
of a layer of PET having a thickness of about 0.00048 inch, a thin
metal film (e.g., aluminum), a thin layer of adhesive (e.g., an
adhesive available as Tycel), and a bottom layer composition
available as Surlyn and having a thickness of about 0.002 inch. The
foregoing representative types of laminated films are suitable for
providing so-called "fin sealed" and "three-sided" types of
packaging containers having the PET layer as the outer surface of
those containers.
[0062] One exemplary laminated film possesses; the top or outer
layer being composed of a layer of a material such as Surlyn having
a thickness of 0.002 inch, a thin layer of adhesive, a metal film
(e.g., aluminum) having a thickness of about 0.00035 inch, a thin
layer of adhesive, and a bottom layer of a material such as Surlyn
having a thickness of about 0.002 inch. The foregoing
representative type of laminated film is suitable for providing
so-called "lap seal" types of pouches.
[0063] The present invention can involve the use of equipment,
materials, methodologies and process conditions that are suitably
modified in order to provide the packaging and controlled
atmospheric conditions for the tobacco products that are packaged
pursuant thereto. The atmosphere within the packaging materials can
be modified in a variety of ways. For example, a significant amount
of the atmosphere within the package can be removed (e.g., by using
vacuum packaging types of techniques), or the atmosphere within the
package can be altered in a controlled manner (e.g., by using gas
flushing types of techniques). The atmosphere within the packaging
materials can also be controlled through the use of oxygen
absorbers, such as those sold by Sorbent Systems, or combination
oxygen and carbon dioxide absorbers, such as those sold by
Everfresh USA. Representative aspects of various technologies
associated with modified atmosphere packaging and controlled
atmosphere packaging are set forth in Analysis and Evaluation of
Preventative Control Measures for the Control and
Reduction/Elimination of Microbial Hazards on Fresh and Fresh-Cut
Product; Chapter VI; Microbiological Safety of Controlled and
Modified Atmosphere Packaging of Fresh and Fresh-Cut Product; U.S.
Food and Drug Administration, Center for Food Safety and Applied
Nutrition (Sep. 30, 2001); which is incorporated herein by
reference.
[0064] The controlled or modified atmospheres within packaged
tobacco products of the present invention can vary. Typically, when
tobacco product is vacuum packed or flushed so as to have a
controlled or modified atmosphere (e.g., even if the atmosphere is
controlled in a manner such that the atmospheric pressure within
the sealed package is at a positive pressure relevant to ambient
atmospheric pressure), atmospheric conditions within the package
are controlled such that a significant amount, and most preferably
virtually all of the oxygen present within with package, is removed
from that package prior to the time that the package is sealed.
That is, less than about 8 percent, and often less than about 6
percent, of the weight of the controlled atmosphere initially
present with a sealed outer package is composed of oxygen. For
example, when the package is sealed, the atmosphere present within
the package preferably can possess less than about 5 percent
oxygen, and most preferably between about 1 percent oxygen and
about 5 percent oxygen, based on the weight of the controlled
atmosphere initially present within that sealed package. Typically,
when the tobacco product is flushed with a gaseous species (e.g., a
selected gas or mixture of gases), a significant amount, and most
preferably virtually all, of the atmosphere within the sealed
package is provided by the desired gaseous species. Exemplary
gaseous species include nitrogen, argon, carbon dioxide, and the
like (e.g., high purity gases that are greater than about 99
percent pure, by weight). Alternatively, the atmosphere to which
the tobacco product incorporates a relatively high level of a
desired gaseous species (e.g., oxygen) in order to introduce the
effects of "gas shock" to the tobacco product (e.g., relatively
high levels of oxygen in the atmosphere can be desirable for the
introduction of "oxygen shock" for purposes of inhibiting enzymatic
discoloration, preventing anaerobic fermentation reactions, and
inhibiting aerobic and anaerobic microbial growth). For example, a
controlled atmosphere containing an amount of oxygen such that the
level of oxygen in that atmosphere greater than about 25 percent by
weight, often greater than about 30 percent by weight, can provide
conditions suitable for introduction of oxygen shock.
[0065] Representative equipment useful for carrying out process
steps associated with the packaging aspects of the present
invention is available from Winpak Ltd. (eg., systems identified as
LD32, L25, L18 and L12); as Linium 300 Series horizontal flow
wrapping systems from Doboy Inc. (e.g., Linium Model Nos. 301, 302,
303, 304 or 305); as Hiwrap 504 systems available from Hitech
Systems s.r.l.; and as the types of systems available from Rovema
Verpackungmaschinen GmbH. Preferred equipment provides a wrapping
material that provides a seal that does not allow passage of gases
or moisture therethrough (e.g., a seal that might be considered as
"air tight").
[0066] Representative blister pack packaging materials can vary.
Exemplary materials used for the lower layer of a typical blister
pack packaging material are laminated polymer films available as
Pentapharm alfoil T-250/25/90, Pentapharm ACLAR PA 180/02,
Pentapharm ACLAR PA 200/02, and Pentapharm ACLAR PA 300/02, from
Klockner-Pentaplast of America, Inc. Exemplary materials used for
the upper layer of a typical blister pack packaging material are
heat sealable metal films. An exemplary heat sealable film is an
aluminum film having a thickness of about 0.0007 inch coated on the
sealing side with a heat sealable material (e.g., Surlyn) that has
a thickness of about 0.0001 inch. See, also, for example, the types
of materials set forth in US Pat. Pub. No. 2004/0043165 to Van
Hulle et al.; which is incorporated herein by reference. Although
so-called "pealable lid" types of blister packages can be employed,
off particular interest are the so-called "push through" types of
blister packages.
[0067] If desired, the packaging can be carried out in a controlled
environment. That is, pasteurized tobacco product can be packaged
in outer packages in a sterile environment.
[0068] Products of the embodiments herein may be packaged and
stored in much the same manner that conventional types of smokeless
tobacco products are packaged and stored. For example, a plurality
of packets or pouches may be contained in a cylindrical container.
If desired, moist tobacco products (e.g., products having moisture
contents of more than about 20 weight percent) may be refrigerated
(e.g., at a temperature of less than about 10.degree. C., often
less than about 8.degree. C., and sometimes less than about
5.degree. C.). Alternatively, relatively dry tobacco products
(e.g., products having moisture contents of less than about 15
weight percent) often may be stored under a relatively wide range
of temperatures.
[0069] For preferred embodiments herein, smokeless tobacco
composition is packaged in such a manner that there is no
requirement for the necessity of refrigeration during periods of
transport and prior to sale. That is, shipping, handling and
storage can be simplified, and the periods during which shipping,
handling and storage are carried out can be prolonged, while the
quality of the smokeless product can be maintained. In addition,
though the shelf life of the product can be prolonged, thus
negating the necessity of refrigeration, the shelf life of
refrigerated product also can be prolonged. Product packaged in
accordance with the embodiments herein can be stored for prolonged
periods of time, while maintaining its overall freshness,
maintaining its moisture content, maintaining its visual appearance
(e.g., not undergoing significant discoloration), maintaining its
sensory properties, not experiencing absorption of undesirable
flavors or odors, and not undergoing change in its overall chemical
nature due to the action of microbial species, including any
significant changes to its pH level. Moist tobacco product (e.g.,
products having moisture contents of more than about 20 weight
percent, and often more than about 30 weight percent) can be stored
for prolonged periods of time without the necessity of
refrigeration.
[0070] The following examples are provided to illustrate further
certain aspects of the embodiments herein, but should not be
construed as limiting the scope thereof. Unless otherwise noted,
all parts and percentages are by weight.
EXAMPLE 1
[0071] A tobacco formulation in the form of a somewhat flat strip
or film is provided in the following manner.
[0072] Tobacco material, comprised of a mixture of cured and aged
flue-cured, burley and Oriental lamina is provided in a strip or
leaf form, and at a moisture of about 9 percent. A portion of this
tobacco mixture is washed with water, and the solubles or
extractable portion that is collected is discarded, and the
remaining water insoluble solids (e.g., pulp portion) is dried. The
resulting dried pulp portion then is mixed with the retained
untreated portion of the original tobacco mixture. That tobacco
mixture then is milled to a particle size that passes through a 150
Tyler mesh screen.
[0073] The resulting tobacco mixture is further mixed with other
ingredients to form the a formulation that contains about 40 parts
of milled tobacco lamina, about 25 parts calcium carbonate, about
15 parts binder (which may be composed of pectin, gelatin, sodium
alginate and starch), about 15 parts glycerin, about 4 parts
flavoring, and about 1 part sucralose or about 1 part sweetening
agent available as SucraSweet HIS 600 from Sweetener Solutions LLC
(on a dry weight basis). The binder can be a suitable binding agent
(e.g., food grade type binding agent), and exemplary binding agents
can be selected from a variety of pectins, gelatins, alginates
(e.g., sodium alginate) or starches. The resulting dry mixture is
dispersed in deionized water (e.g., about 8 to about 10 parts dry
mixture in about 90 to about 92 parts water) to form a slurry that
exhibits a Brookfield viscosity of about 20,000 centipoise to
25,000 centipoise at 25.degree. C.
[0074] The slurry is cast as a thick, uniform layer onto a
stainless steel drying tray, which can be lightly coated with a
non-stick spray before casting the slurry. The tray is placed in a
drying oven at relatively low heat (e.g., about 60.degree. C. to
about 70.degree. C.) for up to about 10 hours (e.g., about 6 to
about 8 hours). As such, a formed mixture of tobacco formulation
components is provided in a desired shape from an aqueous slurry of
those components.
[0075] The slurry can be cast in the shape of a strip (e.g., having
a length of about 25 cm to about 35 cm) and a width of about 1 cm
to about 2 cm. If desired, optional perforation or weakness lines
that extend generally perpendicular to the longitudinal axis of the
strip can be stamped into the strip at predetermined intervals. The
resulting product, which can be formulated and dried so as to be
pliable and possess an acceptably high tensile strength, can be
coiled and incorporated within the type of container described
previously with reference to FIG. 6. That container then can be
packaged within an outer package, and under controlled atmospheric
conditions, of the general type described previously. In use, the
outer package can be opened, and a piece of the long strip of
tobacco formulation extending from an opening on the container can
be broken off in the desired amount for use.
[0076] The slurry can be cast as a sheet or film, and upon drying,
individual portions can be stamped, punched or cut from that sheet
or film. Thus, for example, rectangular strips or sheets, or
circular pieces can be provided from the sheet or film; and
packaged as individual portions (e.g., using outer wrapping
material configured in the general manner described previously with
reference to FIG. 1). The slurry can also be cast into other shapes
or cut into a grid of squares. Furthermore, the sheet or film could
be surface treated to emboss the surface, or a screen can be used
to press a grid into the surface. Shapes and words could also be
imprinted. Flavored ink could also be used to stamp words or shapes
on the surface of the sheet or film.
[0077] Cast material that has been dried can be ground into a
powder or granulated form, and then packed within a moisture
permeable pouch and sealed. Each such pouch can be packaged in an
outer package, in the manner described previously with reference to
FIG. 1.
EXAMPLE 2
[0078] The smokeless tobacco products that are preferably
non-chewable tobacco products that are intended to be placed
between the cheek and the gum of the mouth are provided as follows.
Preferred smokeless tobacco products, when used orally, completely
dissolve in the mouth leaving little to no solid or granular
residue, while dispensing or dispersing tobacco components, and
while providing a pleasant trigeminal and organoleptic
experience.
[0079] Cured and/or aged tobacco lamina or stems is provided in a
strip or shredded form, and at a moisture content of about 9
percent, or less. Tobacco types can include flue-cure, burley and
Oriental tobaccos, and various combinations thereof. In addition,
specialty or exotic types of tobaccos, including tobaccos such as
Perique and Cavendish, also can be incorporated within blends of
tobacco materials. The lamina or stem is milled under cryogenic
conditions, or any other suitable dry milling means, to a fine
ground form. The powder is sufficiently fine so as to pass through
a 150 Tyler mesh screen. The resulting powder then is irradiated
with about 5 to about 20 kilo Grays of gamma radiation.
[0080] Flue cured tobacco lamina that has been aged is provided in
a strip form, and at a moisture content of about 9 percent or less.
The lamina is milled under cryogenic conditions or any other
suitable dry milling means to a fine ground form. The powder is
sufficiently fine so as to pass through a 150 Tyler mesh screen.
The resulting powder then is irradiated with about 5 to about 20
kilo Grays of gamma radiation.
[0081] The tobacco powder is introduced into a fluidized bed. While
in the fluidized bed, the tobacco powder is introduced to a mixture
of water and various other ingredients that have been provided in a
dry powder form. The resulting mixture is removed from the
fluidized bed, and dried to a moisture content of about 4
percent.
[0082] The resulting tobacco formulation is removed from the
fluidized bed. A representative formulation contains about 25 to
about 40 parts of the granulated flue-cured tobacco lamina, about
0.5 to about 3.0 parts of sucralose (modified sugar), about 1 part
titanium dioxide (color modifier), about 10 to about 25 parts
calcium carbonate (in the form available as HD PPT Fine from Ruger
Chemical), about 15 to about 30 parts mannitol powder, about 2 to
about 5 parts powdered cellulose (in the form available as QC-90
from CreaFill Fibers), about 5 to about 15 parts pregelatinized
corn starch (in the form available as Starch 1500 from Colorcon),
about 3 to about 6 parts povidone (in the form available as PVPK-30
from Xian Medicines & Health Products), and about 0.75 to about
2.5 parts potassium hydroxide. The moisture content of the
resulting granulated tobacco formulation is about 4 percent. The
resultant granulated tobacco formulation is a dry, free flowing,
finely milled powder that is light tan in color, and is made up of
particles having an average particle size sufficient to pass
through a screen of about 80 Tyler mesh.
[0083] A desired amount of the tobacco formulation (e.g., about 0.5
g to about 1 g) of the tobacco formulation can be placed within a
sealed fleece pouch, and that pouch can be packaged within an outer
package, such as in the general manner set forth previously with
reference to FIG. 1.
EXAMPLE 3
[0084] A dry mix of about 200 g to about 225 g of granulated
tobacco powder of the type described previously in Example 2, a
flavoring agent (e.g., mint flavor) and optionally sodium chloride
are mixed for about 5 minutes in a table-top Model P400 Popiel.TM.
Automatic Pasta Maker (available from Ronco Inventions, LLC,
Chestworth, Calif.). Then, about 48 g portion of a premixed warm
aqueous solution (e.g., about 40 g water and about 8 g glycerin) is
added to the dry mix. Those contents are mixed for about 3 minutes,
or until small pea-like size lumps develop. The pea-like mixture is
subsequently extruded via selected dies to obtain flat pasta-like
sheets (1.4 cm wide.times.30 cm length.times.0.1 to 0.7 cm depth)
or noodle-like cylindrical rods (0.1 to 0.7 cm diameter.times.12 to
24 cm length). The pasta-like sheet is further cut into smaller
square or rectangular pieces to obtain pellets that each weigh
about 185 mg to about 250 mg. Generally wafer shaped pieces, each
weighing about 185 mg to about 250 mg, also can be punched out of
the pasta-like sheets. The noodle-like rods are further cut to
obtain smaller cylindrical pellet pieces or strands, each weighing
about 185 mg to about 250 mg. Generally wafer shaped pieces (e.g.,
generally cylindrically shaped pieces), each weighing about 185 mg
to about 250 mg, also can be cut from extruded cylindrical rods
(e.g., a continuous cylindrical extrudate can be cut generally
perpendicular to its longitudinal axis). Alternatively, thin
cylindrical extrudate can be similarly subdivided to provide
somewhat longer, stick-like pieces that weight about 150 mg to
about 250 mg. The various shaped pieces are placed onto a stainless
steel plate and dried by ambient temperatures for up to about 24
hours (e.g., for about 12 to about 20 hours). Alternatively, the
pieces are dried either via forced air ovens operated at about
50.degree. C. to about 100.degree. C. for up to 15 minutes, or over
steam from boiling water baths. The dried products typically
exhibit moisture contents of about 5 to about 10 percent. Typical
tobacco formulations exhibit, on a dry weight basis, about 85 to
about 99 parts of the granulated tobacco powder, about 1 to about
15 parts flavoring agent, and about 1 to about 1.5 parts optional
sodium chloride.
[0085] The various tobacco formulations can be packaged in the
manner set forth previously with reference to FIG. 1 through FIG. 5
and FIG. 7.
EXAMPLE 4
[0086] Tobacco formulations having the general size and shape of
those set forth previously in Example 3 are provided, using the
types of preparation techniques set forth in Example 3. However,
the granulated tobacco powder that is employed in Example 3 is
replaced with a finely milled tobacco powder that is prepared as
follows.
[0087] Flue cured tobacco lamina that has been aged is provided in
a strip form, and at a moisture content of about 9 percent or less.
The lamina is milled under cryogenic conditions or any other
suitable dry milling means to a fine ground form. The powder is
sufficiently fine so as to pass through a 150 Tyler mesh screen.
The resulting powder then is irradiated with about 5 to about 20
kilo Grays of gamma radiation.
[0088] The powdered tobacco lamina and various other dry
ingredients are premixed in an automated tumbling mixer for about
15 minutes. As such, on a dry weight basis, a dry mix is prepared
from about 122.5 g of the tobacco powder, about 80.5 g cane sugar,
about 52.5 g precipitated calcium carbonate, about 17.5 g mannitol,
about 48 g rice starch (pregelatinized) and about 1.7 g vanilla
flavoring. Then, that dry mix is combined with about 100 g of warm
water (e.g., at about 30.degree. C. to about 45.degree. C.) having
about 4.6 g of potassium hydroxide dissolved therein in the pasta
maker described in Example 3.
[0089] Tobacco formulations of the type generally set forth in
Example 3 are provided. That is, the tobacco formulations can be
formed into desired shapes, such as sheets, strips, pellets,
sticks, and the like. The shaped tobacco formulations can be
packaged using the types of outer packaging materials set forth
hereinbefore.
EXAMPLE 5
[0090] Tobacco formulations are provided in the manner set forth
previously in Example 4. However, the tobacco formulation
ingredients are formulated as follows. The powdered tobacco lamina
described in Example 4, and various other dry ingredients are
premixed in an automated tumbling mixer for about 15 minutes. As
such, on a dry weight basis, a dry mix is prepared from about 60 g
of the tobacco powder, about 50 g cane sugar, about 34 g
precipitated calcium carbonate, about 20 g mannitol, about 20 g
rice starch (pregelatinized), about 10 g maltodextrin, about 5.2 g
microcrystalline cellulose (available as Ticacel HV from TIC Gums),
about 0.8 g vanilla flavoring, about 0.5 g menthol and about 3.5 g
glycerol tristearate. Then, that dry mix is combined with about 50
g of warm water (e.g., at about 30.degree. C. to about 45.degree.
C.) having about 2 g of potassium hydroxide dissolved therein in
the pasta maker described in Example 3.
EXAMPLE 6
[0091] Tobacco formulations are provided in the manner set forth
previously in Example 4. However, the tobacco formulation
ingredients are formulated as follows. A powdered tobacco lamina is
provided from flue-cured and burley tobacco lamina, in the general
manner set forth in Example 4. In addition, in the general manner
set forth in Example 4, that powdered tobacco lamina, and various
other dry ingredients are premixed in an automated tumbling mixer
for about 15 minutes. As such, on a dry weight basis, a dry mix is
prepared from about 64 g of the tobacco powder, about 4.4 g of a
sweetening agent available as SucraSweet HIS 600 from Sweetener
Solutions LLC, about 40 g precipitated calcium carbonate, about 42
g mannitol, about 19 g rice starch (pregelatinized), about 9 g
hydroxypropylmethylcellouse available as Klucel EF from Hercules,
Inc. and about 5 g microcrystalline cellulose (available as Ticacel
HV from TIC Gums). Then, that dry mix is combined with about 50 g
of warm water (e.g., at about 30.degree. C. to about 45.degree. C.)
having about 2.5 g of potassium hydroxide and about 8 g glycerin
dissolved therein in the pasta maker described in Example 3.
EXAMPLE 7
[0092] Tobacco formulations are provided in the manner set forth
previously in Example 4. However, the tobacco formulation
ingredients are formulated as follows. A powdered tobacco lamina is
provided from flue-cured and burley tobacco lamina, in the general
manner set forth in Example 4. In addition, in the general manner
set forth in Example 4, that powdered tobacco lamina and various
other dry ingredients are premixed in an automated tumbling mixer
for about 15 minutes. As such, on a dry weight basis, a dry mix is
prepared from about 64 g of the tobacco powder, about 4.4 g of a
sweetening agent available as SucraSweet HIS 600 from Sweetener
Solutions LLC, about 40 g precipitated calcium carbonate, about 42
g mannitol, about 19 g rice starch (pregelatinized), about 9 g
sodium alginate available as Kelvis from International Specialty
Products Corp., about 2 g of mint flavoring agent and about 5 g
microcrystalline cellulose (available as Ticacel HV). Then, that
dry mix is combined with about 40 g of warm water (e.g., at about
30.degree. C. to about 45.degree. C.) having about 2.5 g of
potassium hydroxide and about 8 g glycerin dissolved therein in the
pasta maker described in Example 3.
EXAMPLE 8
[0093] A tobacco composition having the form of a multi-layered,
multi-flavored, co-extruded pellet is provided as follows.
[0094] Granulated tobacco powder and other dry ingredients are
again used as described in Example 1, to make a two layered pellet
smokeless tobacco formulation. The pellet can be characterized as
having a shape that might be considered to "pillow-type" in nature
(i.e., the top, bottom, sides and ends are made up by the outer
layer or over layer, and the inner layer is contained within the
outer layer).
[0095] The inner layer is provided by mixing about 200 g granulated
flue-cured tobacco powder, about 6 g sodium chloride and about 1.5
g menthol powder. Then, that dry mix is combined with about 42 g of
warm water (e.g., at about 30.degree. C. to about 45.degree. C.)
having about 8 g of glycerin dissolved therein in the pasta maker
described in Example 3. The inner layer is generally cylindrical
and is made as noodle-like rod.
[0096] The outer layer is provided by mixing about 200 g granulated
flue-cured tobacco powder, about 5 g sodium chloride and about 14 g
of a finely milled burley tobacco powder. The outer layer is made
as a pasta-like flat sheet containing more fine tobacco powder, as
but less flavoring agent than the inner layer.
[0097] To make the smokeless tobacco composition, the pasta-like
sheet is wrapped completely around the thin noodle-like rod. The
enwrapped rod is then cut into smaller cylindrical pellets, and
both cut ends molded or sealed to form small pillow-like pellets,
each pellet weighing about 185 mg to about 250 mg. The pellets are
ambient temperature dried over about 12 hours, or dried for about
20 minutes in a forced air oven set at about 50.degree. C. to about
80.degree. C.
[0098] It will be understood that the inner and outer layers may be
formulated in various ways; for example one layer may be produced
to differ from the other in its level of tobacco sensory
properties, such as by varying the level of flavorings or by using
differing mixtures of tobacco compositions or formulations.
Moreover, in addition to co-extrusion, the multi-layering can also
be achieved by physically wrapping a preformed outer layer around a
preformed inner layer. Alternatively, an inner layer portion may be
laminated between two outer layer portions of slightly larger
lateral dimensions, and the outer layers may then be sealed
together at their edges to envelop the inner layer.
[0099] The tobacco formulation so formed can be packaged within an
outer package of the type described previously with reference to
FIG. 1.
EXAMPLE 9
[0100] A tobacco composition having the general form of a tape or
roll is provided as follows.
[0101] Fine tobacco powder containing a mixture of flue-cure and
burley is premixed in a tumbling mixer for 15 minutes with other
ingredients. As such, a dry mix that is provided contains about 60
g granulated tobacco material, about 3.4 g of a sweetening agent
available as SucraSweet HIS 600, about 36 g precipitated calcium
carbonate, about 40 g mannitol, about 20 g rice starch
(pregelatinized), about 10 g sodium alginate available as Kelvis
from International Specialty Products Corp., about 3 g of menthol
flavor, about 5 g cinnamon flavor and about 4 g microcrystalline
cellulose (available as Ticacel HV). Then, that dry mix is combined
with about 42 g of warm water (e.g., at about 30.degree. C. to
about 45.degree. C.) having about 8 g of glycerin and about 2.6 g
potassium hydroxide dissolved therein in the pasta maker described
in Example 3. The aqueous solution is then gently added to the dry
mix in the pasta maker and mixed for 3 minutes or until pea-like
size lumps are formed. The blend is then extruded into flat
pasta-like sheets of dimension about 1.4 cm wide by about 30 cm
long, by about 0.1 cm to about 0.3 cm thick. Each sheet is further
perforated at intervals of about 0.5 to about 1.5 cm intervals
length-wise to obtain a roll or tape-like product from which square
or rectangular pieces can easily be cut off. Samples are preferably
not fully dried; and hence, maintain prolonged pliability,
elasticity, and tensile strength. The moisture content of the
tobacco composition ranges from about 12.5 to about 25 percent.
[0102] The tape-like product can be formed into a roll, and
positioned within an outer container of the type described
previously with reference to FIG. 6. That outer container then can
be wrapped with an outer wrapping material, using packaging
conditions such as those of the type described hereinbefore.
EXAMPLE 10
[0103] A tobacco composition having the general form of a tape or
roll is provided as follows.
[0104] Fine tobacco powder containing a mixture of flue-cure and
burley is premixed in a tumbling mixer for 15 minutes with other
ingredients. As such, a dry mix that is provided contains about 52
g granulated tobacco material, about 2 g of a sweetening agent
available as SucraSweet HIS 600, about 30 g precipitated calcium
carbonate, about 27.5 g rice starch (pregelatinized), about 40 g
sodium alginate available as Manucol LD from ISP Corporation, about
12 g sodium alginate available as Kelvis from ISP Corporation,
about 3 g of menthol flavor, about 5 g cinnamon flavor and about 4
g microcrystalline cellulose (available as Ticacel HV). Then, that
dry mix is combined with about 40 g of warm water (e.g., at about
30.degree. C. to about 45.degree. C.) having about 16 g of glycerin
and about 7 g sodium carbonate dissolved therein in the pasta maker
described in Example 3. The aqueous solution is then gently added
to the dry mix in the pasta maker and mixed for 3 minutes or until
pea-like size lumps are formed. The blend is then extruded into
flat pasta-like sheets of dimension about 1.4 cm wide by about 30
cm long, by about 0.1 cm to about 0.3 cm thick. Each sheet is
further perforated at intervals of about 0.5 to about 1.5 cm
intervals length-wise to obtain a roll or tape-like product from
which square or rectangular pieces can easily be cut off. Samples
are preferably not fully dried; and hence, maintain prolonged
pliability, elasticity, and tensile strength. The moisture content
the tobacco composition ranges from about 12.5 to about 25
percent.
[0105] The tape-like product can be formed into a roll, and
positioned within an outer container of the type described
previously with reference to FIG. 6. That outer container then can
be wrapped with an outer wrapping material, using packaging
conditions such as those of the type described hereinbefore.
EXAMPLE 11
[0106] A tobacco composition having the general form of a tape or
roll is provided as follows.
[0107] A dry mix that is provided contains about 9 g rice starch
(pregelatinized), about 20 g sodium alginate available as Manucol
LD, about 5 g cinnamon powder and about 3 g menthol powder. Then,
that dry mix is combined with about 40 g of warm water (e.g., at
about 30.degree. C. to about 45.degree. C.) having about 16 g of
glycerin dissolved therein in the pasta maker described in Example
3. During operation of the pasta maker, about 142 g of granulated
tobacco material of the type described in Example 10 is introduced
into the pasta maker along with the previously described aqueous
mix.
[0108] The resulting blend is then extruded into flat pasta-like
sheets of dimension about 1.4 cm wide by about 30 cm long, by about
0.1 cm to about 0.3 cm thick. Each sheet is further perforated at
intervals of about 0.5 to about 1.5 cm intervals length-wise to
obtain a roll or tape-like product from which square or rectangular
pieces can easily be cut off. Samples are preferably not fully
dried; and hence, maintain prolonged pliability, elasticity, and
tensile strength. The moisture content the tobacco composition
ranges from about 12.5 to about 25 percent.
[0109] The tape-like product can be formed into a roll, and
positioned within an outer container of the type described
previously with reference to FIG. 6. That outer container then can
be wrapped with an outer wrapping material, using packaging
conditions such as those of the type described hereinbefore.
EXAMPLE 12
[0110] A tobacco composition having the general form of a tape or
roll is provided as follows.
[0111] A dry mix that is provided contains about 20 g sodium
alginate available as Manucol LD and about 5 g mint flavor. Then,
that dry mix is combined with about 50 g of warm water (e.g., at
about 30.degree. C. to about 45.degree. C.) having about 16 g of
glycerin dissolved therein in the pasta maker described in Example
3. During operation of the pasta maker, about 195 g of granulated
tobacco material of the type described in Example 10 is introduced
into the pasta maker along with the previously described aqueous
mix.
[0112] The resulting blend is then extruded into flat pasta-like
sheets of dimension about 1.4 cm wide by about 30 cm long, by about
0.1 cm to about 0.3 cm thick. Each sheet is further perforated at
intervals of about 0.5 to about 1.5 cm intervals length-wise to
obtain a roll or tape-like product from which square or rectangular
pieces can easily be cut off. Samples are preferably not fully
dried; and hence, maintain prolonged pliability, elasticity, and
tensile strength. The moisture content the tobacco composition
ranges from about 12.5 to about 25 percent.
[0113] The tape-like product can be formed into a roll, and
positioned within an outer container of the type described
previously with reference to FIG. 6. That outer container then can
be wrapped with an outer wrapping material, using packaging
conditions such as those of the type described hereinbefore.
EXAMPLE 13
[0114] A combination of finely milled flue-cure and burley tobacco
powder (e.g., about 25 g) is mixed with about 100 ml of a solution
having about 1 g potassium hydroxide in about 100 ml water. The
resulting slurry is heated with constant stirring to about
60.degree. C. to about 80.degree. C. for about 15 minutes. About 1
g of a sweetening agent available as SucraSweet HIS 600 and about
15 g mannitol then are added, and the slurry is held at about
60.degree. C. to about 80.degree. C. for another 15 minutes, while
mixing constantly to obtain a tobacco/water slurry. Meanwhile, a
binder system is prepared separately in a Warring blender. About 5
g sodium alginate available as Kelvis is first mixed at high shear
with about 200 ml water for 5 minutes, followed by the slow
addition of about 20 parts sodium alginate available as Manucol LD,
about 7 g rice starch (pregelantinized), about 2 g microcrystalline
cellulose available as Ticacel, about 10 g calcium carbonate and
about 15 g glycerin, successively, while the blender is operated at
medium to high shear speed for approximately another 10 minutes.
The binder and tobacco slurry mixtures are then mixed together in
the blender at medium to high shear speed for approximately another
5 minutes, with the addition of the about 2.5 g cinnamon and about
1.5 g menthol. After mixing, portions of the final slurry are cast
at about 0.1 cm to about 0.3 cm thickness onto a stainless steel
plate. The slurries are then dried to form tobacco sheets or films
weighing about 95 g to about 125 g per square meter. The sheets are
finally cut into smaller square or rectangular pieces, each
weighing about 50 mg to about 150 mg. The resulting pieces have the
form of relatively slow dissolving strips. Those strips can be
individually packaged in outer packaging materials of the type
described previously with reference to FIG. 1.
EXAMPLE 14
[0115] A combination of finely milled flue-cure and burley tobacco
powder (e.g., about 25 g) is mixed with about 100 ml of a solution
having about 2 g sodium carbonate in about 100 ml water. The
resulting slurry is heated with constant stirring to about
60.degree. C. to about 80.degree. C. for about 15 minutes. About 1
g of a sweetening agent available as SucraSweet HIS 600 then is
added, and the slurry is held at about 60.degree. C. to about
80.degree. C. for another 15 minutes, while mixing constantly to
obtain a tobacco/water slurry. Meanwhile, a binder system is
prepared separately in a Warring blender. About 6 g sodium alginate
available as Kelvis is first mixed at high shear with about 200 ml
water for 5 minutes, followed by the slow addition of about 20 g
rice starch (pregelantinized), about 10 g maltodextrin, about 15 g
calcium carbonate and about 15 g glycerin, successively, while the
blender is operated at medium to high shear speed for approximately
another 10 minutes. The binder and tobacco slurry mixtures are then
mixed together in the blender at medium to high shear speed for
approximately another 5 minutes, with the addition of the about 4.9
g mint flavor. After mixing, portions of the final slurry are cast
at about 0.1 cm to about 0.3 cm thickness onto a stainless steel
plate. The slurries are then dried to form tobacco sheets or films
weighing about 95 g to about 125 g per square meter. The sheets are
finally cut into smaller square or rectangular pieces, each
weighing about 50 mg to about 150 mg. The resulting pieces have the
form of relatively slow dissolving strips. Those strips can be
individually packaged in outer packaging materials of the type
described previously with reference to FIG. 1.
EXAMPLE 15
[0116] A combination of finely milled flue-cure and burley tobacco
powder (e.g., about 15 g) is mixed with about 100 ml of a solution
having about 1.75 g sodium carbonate in about 100 ml water. The
resulting slurry is heated with constant stirring to about
60.degree. C. to about 80.degree. C. for about 15 minutes. About
0.5 g of a sweetening agent available as SucraSweet HIS 600 and
about 7.5 g mannitol then are added, and the slurry is held at
about 60.degree. C. to about 80.degree. C. for another 15 minutes,
while mixing constantly to obtain a tobacco/water slurry.
Meanwhile, a binder system is prepared separately in a Warring
blender. About 7.5 g konjac flour available as Nutritol GP 312 from
FMC Bioplolymers Corporation is first mixed at high shear with
about 200 ml water for 5 minutes, followed by the slow addition of
about 15 g calcium carbonate, about 0.75 g sodium chloride and
about 7.5 g glycerin, successively, while the blender is operated
at medium to high shear speed for approximately another 10 minutes.
The binder and tobacco slurry mixtures are then mixed together in
the blender at medium to high shear speed for approximately another
5 minutes, with the addition of the about 1.25 cinnamon and about
0.75 g menthol. After mixing, portions of the final slurry are cast
at about 0.1 cm to about 0.3 cm thickness onto a stainless steel
plate. The slurries are then dried to form tobacco sheets or films
weighing about 95 g to about 125 g per square meter. The sheets are
finally cut into smaller square or rectangular pieces, each
weighing about 50 mg to about 150 mg. The resulting pieces have the
form of relatively slow dissolving strips. Those strips can be
individually packaged in outer packaging materials of the type
described previously with reference to FIG. 1.
EXAMPLE 16
[0117] A combination of finely milled flue-cure and burley tobacco
powder (e.g., about 15 g) is mixed with about 100 ml of a solution
having about 1.75 g sodium carbonate in about 100 ml water. The
resulting slurry is heated with constant stirring to about
60.degree. C. to about 80.degree. C. for about 15 minutes. About
0.75 g of a sweetening agent available as SucraSweet HIS 600 then
is added, and the slurry is held at about 60.degree. C. to about
80.degree. C. for another 15 minutes, while mixing constantly to
obtain a tobacco/water slurry. Meanwhile, a binder system is
prepared separately in a Warring blender. About 3.5 g sodium
alginate available as Kelvis is first mixed at high shear with
about 200 ml water for 5 minutes, followed by the slow addition of
about 9.5 g rice starch (pregelatinized), about 5 g maltodextrin,
about 5 g calcium carbonate, about 0.75 g sodium chloride and about
7.5 g glycerin, successively, while the blender is operated at
medium to high shear speed for approximately another 10 minutes.
The binder and tobacco slurry mixtures are then mixed together in
the blender at medium to high shear speed for approximately another
5 minutes, with the addition of the about 1.25 cinnamon and about
0.75 g menthol. After mixing, portions of the final slurry are cast
at about 0.1 cm to about 0.3 cm thickness onto a stainless steel
plate. The slurries are then dried to form tobacco sheets or films
weighing about 95 g to about 125 g per square meter. The sheets are
finally cut into smaller square or rectangular pieces, each
weighing about 50 mg to about 150 mg. The resulting pieces have the
form of relatively slow dissolving strips. Those strips can be
individually packaged in outer packaging materials of the type
described previously with reference to FIG. 1.
EXAMPLE 17
[0118] About 50 g of a granulated tobacco powder is mixed with
about 100 ml of water in a Warring blender at low shear speed for
about 5 minutes to obtain an aqueous tobacco slurry. Meanwhile a
binder system is prepared in a separate blender by mixing about 5 g
sodium alginate available as Kelvis with about 200 ml water at high
shear speed for about 5 minutes. About 15 g sodium alginate
available as Manucol LD and about 5 g hydroxypropylcellulose
available as Klucel EF are slowly added, successively, as the
slurry is mixed for approximately another 5 minutes. About 7.5 g
glycerin is then added to the binder system and the slurry mixed
for another 5 minutes. The aqueous tobacco slurry and binder
systems are then mixed together for another 5 minutes at medium to
high shear speed with the addition of about 2 g mint flavor. The
final slurry is subsequently cast, dried, and cut into thin film
strips. Those relatively slow dissolving strips can be individually
packaged in outer packaging materials of the type described
previously with reference to FIG. 1.
EXAMPLE 18
[0119] About 50 g of a granulated tobacco powder is mixed with
about 100 ml of water in a Warring blender at low shear speed for
about 5 minutes to obtain an aqueous tobacco slurry. Meanwhile a
binder system is prepared in a separate blender by mixing about 6 g
sodium alginate available as Kelvis with about 200 ml water at high
shear speed for about 5 minutes. About 10 g sodium alginate
available as Manucol LD is slowly added, as the slurry is mixed for
approximately another 5 minutes. About 14 g glycerin is then added
to the binder system and the slurry mixed for another 5 minutes.
The aqueous tobacco slurry and binder systems are then mixed
together for another 5 minutes at medium to high shear speed with
the addition of about 5 g mint flavor. The final slurry is
subsequently cast, dried, and cut into thin film strips. Those
relatively slow dissolving strips can be individually packaged in
outer packaging materials of the type described previously with
reference to FIG. 1.
EXAMPLE 19
[0120] A moist tobacco formulation in the form for use as a
snus-type smokeless tobacco product is provided in the following
manner.
[0121] Various types of tobacco material are combined. A pre-blend
of several components is made and metered into an AeroFlex Model
A115 flexible screw conveyor (Vac-U-Max Company, Belleville, N.J.).
The flexible screw feeder discharges directly to a Fitzmill
Comminutor hammer mill (Fitzpatrick, Elmhurst, Ill.) utilizing a
concave with 0.125 inch diameter holes. The milled lamina is then
pneumatically conveyed to a Rotex Model 44 screener (Rotex
Corporation, Cincinnati, Ohio) with 2 screens--an 18 Tyler mesh and
a 60 Tyler mesh. The material that does not pass through the 18
mesh screen is conveyed back to the infeed hopper for further
milling and the material passing the 60 mesh is discarded. The
material that passes the 18 mesh and is retained on the 60 mesh is
gravity discharged into a container for further use in the process.
A plurality of stem fractions (Rustica, Kurnool, and Indian Sun
Cured) is milled separately to the same size as the lamina using
the same equipment noted above.
[0122] An amount of each material (lamina, Indian Sun Cured Stem,
Rustica Stem, Kurnool Stem) is loaded into a Scott Mixer. The mixer
shaft rotates at 73 rpm for a minimum of 5 minutes during the
mixing/blending step. Tobacco moisture is 11.43% (by weight) with a
pH of 5.23.
[0123] Water is added to the snus formulation to bring the
formulation to about 45% moisture content. Salt is added at 1.5% of
the dry weight of the snus formulation. The mixture is pasteurized
at 212.degree. F. (100.degree. C.) for one hour. The mixture is
then dried down to about 20-25% moisture content. At this point in
the preparation of the snus-type tobacco formulation, a preferred
buffer is added to the tobacco formulation. The mixture is brought
up to 55% moisture content in a solution of the buffer made up of
sodium carbonate and sodium bicarbonate at a ratio of between about
1:75 and 1:80. The buffer is added to the snus formulation in an
amount that is about 7-15% of the dry weight of the snus
formulation. During this period, the pH goes from about 9-9.5 to
7.8-8.
[0124] The snus-type tobacco formulation is then packaged in
moisture permeable pouches as known in the art, such as pouches
composed of a "fleece" type of material. The pouches are then
contained within a package which is sealed tightly in a controlled
environment, and is composed of a suitable material, such that the
atmospheric conditions within that sealed package are modified by
the addition of carbon dioxide and removal of oxygen from within
the sealed package The sealed package provides a good barrier that
inhibits the passage of compositions such as moisture and oxygen
therethrough. As such, the atmospheric conditions to which the
snus-type tobacco formulation is exposed are controlled during
conditions of preparation, packing, storage and handling. It has
been shown that such a packaging system combined with the use of
the buffer described above can result in up to a 90% reduction in
pH change over the course of accelerated aging processes.
* * * * *