U.S. patent application number 12/180943 was filed with the patent office on 2010-01-28 for smokeless tobacco products and processes.
Invention is credited to William Monroe Coleman, III, Anthony Richard Gerardi, Percy Denoid Phillips.
Application Number | 20100018541 12/180943 |
Document ID | / |
Family ID | 41567536 |
Filed Date | 2010-01-28 |
United States Patent
Application |
20100018541 |
Kind Code |
A1 |
Gerardi; Anthony Richard ;
et al. |
January 28, 2010 |
SMOKELESS TOBACCO PRODUCTS AND PROCESSES
Abstract
A smokeless tobacco product is provided. A tobacco product
configured for insertion into the mouth of a user of that product
comprises a water-permeable pouch containing a tobacco formulation
that includes a granular tobacco composition and miraculin.
Inventors: |
Gerardi; Anthony Richard;
(Winston-Salem, NC) ; Coleman, III; William Monroe;
(Winston-Salem, NC) ; Phillips; Percy Denoid;
(Pfafftown, NC) |
Correspondence
Address: |
BRINKS HOFER GILSON & LIONE
P.O. BOX 10395
CHICAGO
IL
60610
US
|
Family ID: |
41567536 |
Appl. No.: |
12/180943 |
Filed: |
July 28, 2008 |
Current U.S.
Class: |
131/352 |
Current CPC
Class: |
A24B 13/00 20130101;
A24B 15/30 20130101; B65B 37/10 20130101; A24B 15/282 20130101;
B65D 51/20 20130101; A24F 23/00 20130101; B65D 25/04 20130101; B65D
2209/00 20130101 |
Class at
Publication: |
131/352 |
International
Class: |
A24B 13/02 20060101
A24B013/02 |
Claims
1. A tobacco product configured for insertion into the mouth of a
user of that product, the tobacco product comprising: a
water-permeable pouch containing a tobacco formulation, the tobacco
formulation including a granular tobacco composition and
miraculin.
2. A tobacco product configured for insertion into the mouth of a
user of that product, the tobacco product comprising: a tobacco
formulation including a granular tobacco composition enclosed
within a water-permeable pouch, wherein said water-permeable pouch
has been reacted with miraculin.
3. A tobacco product configured for insertion into the mouth of a
user of that product, the tobacco product comprising: a tobacco
formulation including a granular tobacco composition enclosed
within a water-permeable pouch, wherein said water-permeable pouch
is coated with miraculin.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to tobacco products and
packaging for tobacco products in smokeless form, including those
smokeless tobacco products characterized as "snus."
BACKGROUND OF THE INVENTION
[0002] Tobacco 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.
[0003] 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. Pub. No. 2005/0244521 to Strickland et al. and
2006/0162732 to Winn et al.; U.S. Pat. Pub. Nos. 2006/0191548 to
Strickland et al., 2007/0261707 to Winterson et al., 2007/0062549
to Holton, Jr. et al.; 2007/0186941 to Holton, Jr. et al.;
2008/0166395 to Roush; and PCT Pub. Nos. WO 04/095959 to Arnarp et
al.; WO 05/063060 to Atchley et al.; WO 06/004480 to Engstrom; WO
05/041699 to Quinter et al.; and WO 07/138484 to Wrenn 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.
[0004] Representative smokeless tobacco products have been marketed
under the trade names 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, Mammoth Cave by Conwood Sales Co.,
L.P., Interval by Brown & Williamson Tobacco Corp., and Ariva
and Stonewall by Star Scientific, Inc.
[0005] 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 trade names Camel Snus Frost, Camel Snus
Original and Camel Snus Spice by R. J. Reynolds Tobacco
Company.
[0006] Snus products, such as Camel Snus Original, are commonly
supplied in small teabag-like pouches. The pouches are typically a
nonwoven fleece material, and contain about 0.4 to 1.5 grams of
pasteurized tobacco. These products typically remain in a user's
mouth for about 10-30 minutes. Unlike certain other smokeless
tobacco products, snus do not require expectoration by the
user.
[0007] Consumers who formerly used smoking products and switch over
to snus or other pouched tobacco products may find that the initial
feeling in the mouth along the cheek or gum is uncomfortable.
Therefore, there exists a need to improve the initial mouth feel of
the snus pouch.
[0008] The fleece used for snus also may exhibit discoloration
after being stored over time. This discoloration typically displays
as a yellowing of the fleece material. This discoloration can make
the snus pouches unappealing to the consumer. Furthermore, the
consumer may assume that the snus pouch has degraded in some
fashion because of the discoloration, and dispose of the pouch
without using it. There exists a need to reduce this type of
discoloration. Furthermore, snus pouches are typically a whitish
color, and different flavors of snus are not easily distinguished.
There exists a need to have a way to easily identify different snus
flavors from sight alone.
[0009] Problems exist in the art with respect to efficiently
feeding tobacco into pouches. The problems lie in the material flow
through the hopper of the high-speed pouching equipment. The feed
hoppers are subject to dead zones and rat holes due to the
dimensions of the hopper and the properties of the tobacco that is
supplied to the hopper. This causes loss of product flow in the
hopper. Dead zones occur in the lower area of the hopper, where the
slope of the hopper tends to pack the tobacco material against the
bottom wall. Rat holes can occur in multiple areas of the middle
section of the hopper, and like dead zones, they choke off the flow
of tobacco to the feed screw. This requires the operator to
regularly clean this area and push the tobacco back into the feed
screw. This increases production time and lowers production
efficiency. There is a need for improvements to these pouching
machines to improve manufacturing speed and efficiency.
[0010] Snus are also commonly supplied in various flavors such as
Camel Snus Frost and Camel Snus Spice. The snus may be flavored by
mixing flavor into the tobacco, adding microcapsules or the like to
the tobacco, or adding flavor strips to the tobacco. U.S. patent
application Ser. No. 11/781,604 to Dube et al. describes numerous
methods of accomplishing this, and is herein incorporated by
reference in its entirety. Typically, one flavor is supplied in one
package because otherwise, the flavors can leech into each other,
which can adversely affect the taste of all of the flavors.
[0011] However, while a consumer can use a snus pouch almost
anywhere, it is necessary to dispose of the pouch in a convenient
fashion once the consumer is through with it. It would be desirable
to have a method of disposing of a used snus pouch without
necessarily having to conveniently find a suitable disposal
container in a timely manner (e.g. a garbage can . . . etc.). For
example, after a user has finished a snus pouch or other smokeless
tobacco pouch, there is a need to dispose of the pouch. A user must
either find a waste disposal container or simply hold on to the
used pouch if they do not want to litter. A used snus or other
smokeless tobacco pouch is typically damp and unpleasant to keep in
a user's pocket. A user could wrap the pouch in paper or tissue of
some kind, assuming it is handy. Another alternative would be to
put the pouch back in the container, but the used and damp pouch
could negatively affect the unused pouches. Furthermore, with the
onset of more restrictions on smoking, public areas have a reduced
number of ashtrays available for disposal of cigarette butts and
other smoked articles. There is also a need for a simple and
convenient disposal means for such materials that can be carried by
a user. In the case of snuff tins, one method to store used snuff
is to provide a rotatable dividing wall to create a separate
chamber for storing used snuff, as disclosed in PCT Pub. Nos. WO
08/066450 and WO 08/066451, both to Sjoberg et al. Other snus tins
containing separate compartments have been disclosed in U.S. patent
application Ser. No. 29/297,520 to Patel et al. and U.S. patent
application Ser. No. 29/297,517 to Patel et al. Methods of
attaching holding devices for lighters or advertisements on
cigarette boxes are disclosed in U.S. Pat. Pub. No. 2008/0128300 to
Bahar et al. A cigarette box that can convert into an ashtray for
disposal of used cigarette butts is disclosed in U.S. Pat. Pub. No.
2008/0121243 to Galoyan.
[0012] Snus products have been packaged in tins, "pucks" or "pots"
that are manufactured from metal or plastic such as those disclosed
in PCT Pub. Nos. WO 08/066450 and WO 08/066451 to Sjoberg et al. In
certain circumstances, smokeless tobacco products such as snus 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. Another method of
keeping moist smokeless tobacco products fresh by thermally
treating the smokeless tobacco products is disclosed in U.S. Pat.
Pub. No. 2008/0156338 to Winterson et al.
[0013] It would be desirable to provide efficient and improved snus
or other smokeless formulations with improved components, improved
methods of manufacturing, and improved packaging, all associated
with efficient production of products that provide enjoyment and
satisfaction when employed by a user of that smokeless tobacco
product.
SUMMARY OF THE INVENTION
[0014] The present invention relates to packaging for tobacco
products in smokeless form, including those smokeless tobacco
products characterized as "snus." The products include 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, fillers, flavoring agents, disintegration
aids, antioxidants, humectants, and preservatives. The moisture
content of the particles of the tobacco may vary.
[0015] 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, 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.
[0016] In one aspect, a tobacco product configured for insertion
into the mouth of a user of that product comprises a
water-permeable pouch containing a tobacco formulation that
includes a granular tobacco composition and miraculin.
[0017] In one aspect, a tobacco product configured for insertion
into the mouth of a user of that product comprises a tobacco
formulation including a granular tobacco composition enclosed
within a water-permeable pouch that has been reacted with
miraculin.
[0018] In one aspect, a tobacco product configured for insertion
into the mouth of a user of that product, comprises a tobacco
formulation including a granular tobacco composition enclosed
within a water-permeable pouch that is coated with miraculin.
[0019] In one aspect, a tobacco product configured for insertion
into the mouth of a user of that product, comprises a tobacco
formulation including a granular tobacco composition enclosed
within a water-permeable pouch that has been treated with a
substance selected from the group consisting of: an analgesic, a
buffer, a coloring, an effervescent, or an organic acid.
[0020] In one aspect, a container for storing a smokeless tobacco
product comprises an interior and an exterior, with an onsert
attached to the exterior of the container. The onsert comprises a
closed end, an open end, and a flap extending from the open
end.
[0021] In one aspect, a container for storing a smokeless tobacco
product comprises an interior and an exterior, with an onsert
attached to the interior of the container. The onsert comprises a
closed end, an open end, and a flap extending from the open
end.
[0022] In one aspect, a container for storing a smokeless tobacco
product comprises an interior and an exterior, with an onsert
attached to the exterior of the container. The onsert comprises a
flexible bag with a closed portion and an open portion. The
flexible bag has a flat position and an open position.
[0023] In one aspect, a container for storing a smokeless tobacco
product comprises an interior and an exterior, with an onsert
attached to the exterior of the container. The onsert comprises a
pouch having a slot defined in the outer surface of the pouch and
the pouch is squeezable from opposing sides to open the slot and
access the interior of the pouch.
[0024] In one aspect, a container for smokeless tobacco comprises a
lid and a corresponding bottom piece having an outside wall and at
least one dividing wall extending between opposite sides of the
outside wall and dividing the bottom piece into a plurality of
compartments. A seal is removably positioned over each
compartment.
[0025] In one aspect, an improved pouching machine comprises a feed
hopper with a first and a second end and a feed screw with a
plurality of pins extending from the circumference. The feed screw
is connected to a first shaft and the first shaft is connected to a
motor to rotate the first shaft. An agitator screw is positioned
adjacent to the feed screw and has a plurality of pins extending
from the circumference. The agitator screw is connected to a second
shaft.
[0026] In one aspect, an improved tobacco pouching machine
comprises a feed hopper having a first end, a second end, a top and
a bottom with a first rotatable screw positioned near the bottom of
said feed hopper. A second rotatable screw is positioned above the
first rotatable screw, and a pulley system connects the first screw
to the second screw, such that when the first screw rotates, the
second screw rotates in an opposite direction.
[0027] In one aspect, a method for preventing packing of tobacco in
a tobacco hopper, comprises the steps of providing a feed screw
with a plurality of pins extending from an outer diameter of the
feed screw and providing an agitator with a plurality of pins
extending from an outer diameter of said outer diameter. The feed
screw and said agitator screws are rotated in opposite directions
to move tobacco through the hopper.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] 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.
[0029] FIG. 1. is a perspective view of an open container for
smokeless tobacco with part of a removable seal cut away.
[0030] FIG. 2 is a perspective view of an open container for
smokeless tobacco with the top shown in phantom and a removable
seal in place.
[0031] FIG. 3 is a perspective view of an open container for
smokeless tobacco with a removable seal partly removed.
[0032] FIG. 4 is a perspective view of a closed container for
smokeless tobacco.
[0033] FIG. 5 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.
[0034] FIG. 6 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.
[0035] FIG. 7 is a perspective view of a closed container for
smokeless tobacco having a closed onsert attached thereon.
[0036] FIG. 8 is a side plan view of the closed container for
smokeless tobacco of FIG. 7.
[0037] FIG. 9 is a perspective view of the closed container for
smokeless tobacco of FIG. 7 with the onsert in an open
position.
[0038] FIG. 10 is a side plan view of the closed container for
smokeless tobacco of FIG. 9.
[0039] FIG. 11 is a perspective view of a closed container for
smokeless tobacco having a closed onsert attached thereon with a
seal in place over the onsert.
[0040] FIG. 12 is a side plan view of the closed container for
smokeless tobacco of FIG. 11.
[0041] FIG. 13 is a perspective view of the closed container for
smokeless tobacco of FIG. 11 with the seal partially removed.
[0042] FIG. 14 is a side plan view of the closed container for
smokeless tobacco of FIG. 11 with the seal partially removed.
[0043] FIG. 15 is a perspective view of a container for smokeless
tobacco with the top removed and an onsert attached to the interior
of the top.
[0044] FIG. 16 is a perspective view of a closed container for
smokeless tobacco with an onsert attached thereon.
[0045] FIG. 17 is a side perspective view of an infeed and metering
system for a tobacco pouching machine.
[0046] FIG. 18 is a rear perspective view of an infeed and metering
system for a tobacco pouching machine.
[0047] FIG. 19 is a perspective view of a hopper for the infeed and
metering system of a tobacco pouching machine.
[0048] FIG. 20 is a perspective view of the infeed and metering
system of FIG. 17 showing the formation of a dead zone in the
tobacco.
[0049] FIG. 21 is a perspective view of a hopper for the infeed and
metering system of FIG. 19 showing the formation of a rat hole in
the tobacco.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0050] The present inventions now will be described more fully
hereinafter with reference to the accompanying drawings. The
inventions may be embodied in many different forms and should not
be construed as limited to the embodiments set forth herein;
rather, these embodiments are provided so that this disclosure will
satisfy applicable legal requirements. Like numbers refer to like
elements throughout. As used in this specification and the claims,
the singular forms "a," "an," and "the" include plural referents
unless the context clearly dictates otherwise.
[0051] Referring to FIGS. 1-4, a first embodiment of a snus tin 10
is shown such as that disclosed in related U.S. application Ser.
Nos. 29/297,520 and 29/297,517 to Patel et al. A typical tin 10 is
comprised of plastic or metal top 12 and bottom 16 pieces. FIGS.
1-3 show the tin 10 with the top 12 already removed and FIG. 4
shows the closed tin 10.
[0052] A tin 10 is the short, rounded edge, generally cylindrical
container used for the marketing of snus products. See, for
example, the types of representative snuff-box types of designs set
forth in PCT Pub. No. WO 05/016036 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) so 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, so that when an opened container is re-shut, a good seal
is provided.
[0053] Referring to FIGS. 5 and 6, individual pouch sealed tobacco
portions 18 are contained within the tin 10. The number of tobacco
portions 18 within the tin 10 can vary, and can be a number such as
10, 12, 15, 20, 25 or 30. The tin 10 is in turn packaged within a
sealed outer package which is tightly sealed at each end and is
constructed from an appropriate material, such that the atmosphere
22 within that outer package, and within the tin 10, is controlled.
For example, the atmosphere 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. Such a
method is disclosed in U.S. patent application Ser. No. 12/014,525
to Robinson et al., and is herein incorporated by reference in its
entirety. In use, the outer package is opened, the tin 10 is
opened, and individual tobacco portions 18 are removed as desired
from the tin 10.
[0054] Referring to FIGS. 1-3, one embodiment has four separate
compartments 24 are provided. Each compartment 24 may contain a
different flavor of snuff or snus pouches. Alternatively, all the
compartments 24 could contain the same type of smokeless tobacco,
and the provision of the separate compartments allows a user to
open one compartment 24 at a time. The other compartments 24 remain
airtight and the freshness of the smokeless tobacco in the sealed
compartments 24 is not compromised.
[0055] In the embodiment shown in FIG. 3, a single removable flap
26 covers all four compartments 24 and a user peels back the flap
26 to open one or more compartments 24. Alternatively, each
compartment 24 could have an individual flap 28, as shown in FIG.
1, allowing a user to remove one or more flaps to open one or more
compartment 24. The flaps 26, 28 could also be resealable. The
compartments 24 could take any number of shapes. Some could be
larger than others, and contain different amounts or flavors of
smokeless tobacco.
[0056] The flaps 26, 28 can be constructed from various materials
known in the art capable of maintaining an air and moisture tight
seal. For example, metal foil/paper laminates, metalized paper,
plastic wrappers, metalized polymeric film or low permeability
transparent polymeric sheets are effective. Exemplary materials are
disclosed in U.S. Pat. Pub. No. 2004/0217023 to Fagg et al. and
U.S. Pat. No. 7,124,883 to Thomas et al., both of which are herein
incorporated in their entirety. It is preferred to utilize a
low-permeability material for the construction of the tin 10 and
the internal compartment dividers 30 to further reduce flavors or
aromas leeching between the compartments 24. Such a material could
be an injection-moldable polymeric material, typically a
thermoplastic or thermosetting polymer such as polypropylene,
polyethylene terephthalate ("PET") or polyethylene vinyl alcohol.
Other exemplary injection-moldable materials that can be utilized
for the tin 10 and/or the compartment dividers 30 are acrylonitrile
butadiene styrene ("ABS"), polyethylene, polyvinyl chloride ("PVC")
and polystyrene. In order to further reduce the leeching of flavors
into the tin 10 materials and vice versa, the mold can be lined
with aluminum foil such that there is an aluminum layer on the
inside surface 32 of the tin 10.
[0057] The low-permeability material could also be metallic, and
the material used for the lids 12 and body 16 could differ from the
material used for the internal dividers 30. Furthermore, the lid
12, body 16, and internal dividers 30 could all be comprised of
different materials.
[0058] The flaps 26, 28 could also incorporate other features.
Words, colors or pictures could be stamped or printed on the flaps
26, 28 to designate the type of tobacco in each compartment 24. The
material itself could be colored, rather than having color stamped
on it. Adhesives known in the art can be used to seal the flaps 26,
28 in place and to reseal them in place once they have been opened.
Exemplary materials that can be utilized to seal the flaps 26, 28
closed may be low, moderate and high tack reclosable adhesives.
These adhesives can be based on natural rubber, hot melt rubber
(synthetic), acrylic or silicone.
[0059] Referring to FIGS. 7-16, another embodiment of a container
10 for a smokeless tobacco product is shown. In a first embodiment,
the container 10 shown in FIGS. 7-10 includes a package onsert 34
that is capable of holding one or more used smokeless tobacco
pouches 18. With respect to the embodiment above, as previously
stated, the used pouches 18 could be stored in one of the separate
compartments 24 that has already been emptied of pouches 18.
[0060] In this embodiment, the onsert 34 is positioned on the
outside of the smokeless tobacco container 10 as shown in FIGS.
7-10. The onsert 34 is provided in a substantially flat initial
form so that it does not significantly increase the size of the
smokeless tobacco container 10. The onsert 34 is designed to expand
as it is filled. In a first embodiment of such an onsert 34, shown
in FIGS. 7-10, the onsert 34 is an "accordion-type" onsert 34 with
at least one accordion pleat 36 on three sides. The onsert 34 also
has a closed end 42 and an open end 44. The open end 44 is
preferably supplied with a flap 46 that can be folded over the open
end 44. The open end 44 can be on the narrow side 48, as shown in
FIG. 9, or on the wide side 50.
[0061] The flap 46 can be bifold or multifold, and can include
temporary or permanent adhesive to seal the onsert 34 closed.
Exemplary materials that can be utilized to seal the flap 46 closed
may be low, moderate and high tack reclosable adhesives. These
adhesives can be based on natural rubber, hot melt rubber
(synthetic), acrylic or silicone. A further alternative embodiment
of the onsert 34, shown in FIG. 16, includes a slit 52 in the outer
surface 56, with the narrow 48 and wide 50 side surfaces closed. In
use, the sides 48 of the onsert 34 are squeezed together to open
the slit 52 in the outer surface 56. The used pouch 18 is then
placed in the onsert 34.
[0062] The onsert 34 can be made from waterproof or water
impermeable materials such as paper, plastic, foil, waxed paper, or
other commonly used materials. Furthermore, the onsert 34 can be
multi-ply, with one ply being waterproof. For example, an inside
layer 54 can be plastic film while the outer layer 56 is an opaque
material to keep the contents hidden. The opaque layer can further
comprise high-quality graphics such as those used on current
onserts to carry a message to the consumer. An onsert 34 could
further comprise a booklet on the outside surface 56. The onsert 34
can be fixed to the smokeless tobacco container 10 either
permanently or temporarily using common adhesives. Exemplary
materials that can be utilized to affix the onsert 34 to the
smokeless tobacco container 10 may be low, moderate and high tack
reclosable adhesives. These adhesives can be based on natural
rubber, hot melt rubber (synthetic), acrylic or silicone.
[0063] Additionally, the flap 46 of the onsert 34 can be angled as
shown in FIGS. 7 and 9 and one side 56 of the onsert 34 can have a
corresponding slot 58 into which the flap 46 is inserted in order
to hold the flap 46 in place and keep the onsert 34 closed.
Alternatively, the flap 46 can include an adhesive on one side,
such as low, moderate and high tack reclosable adhesives. These
adhesives can be based on natural rubber, hot melt rubber
(synthetic), acrylic or silicone. and can either permanently or
temporarily hold the flap 46 in place.
[0064] In an alternative embodiment shown in FIGS. 11-15, the
onsert can be an appropriately sized plastic bag 60 with one open
end 62. The bag 60 is sealed on three other sides 64. The bag 60 is
attached to a substrate 70 coated with a reclosable adhesive. The
substrate 70 is sized larger than the bag 60 to leave an adhesive
layer 68 surrounding the bag 60. The substrate 70 can be paper,
plastic or a laminate of paper/plastic, paper/foil, or
plastic/foil, for example. Graphics can be applied to the substrate
which would be visible from the side opposite of the adhesive. The
adhesive side is applied to the container 10. If desired, a folded
corner 72, or edge may be provided to allow for ease in opening.
Alternatively, the corner or edge could be left free of adhesive.
The bag 60 could have a small piece of pressure sensitive tape or
adhesive 74 on one side of the bag 60 to attach bag 60 to the
container 10. When the resealable substrate 70 is lifted, the
substrate 70 pulls the bag 60 open and the adhesive 74 holds the
opposite side of the bag 60 against the outside 56 of the tin 10.
This allows the mouth 62 of the bag 60 to open while the bag 60 is
still attached to the outside 56 of the tin 10. Other tapes could
be used as the substrate or adhesives applied to the substrate as
are known in the art.
[0065] In addition, the inside of the onsert 34 could contain a
disinfectant or sanitizer to allow hygienic storage of the spent
snus pouch 18. Examples of disinfectants include (but are not
limited to) citric acid, thymol, and quarternary ammonium compounds
such as alkyl dimethyl benzyl ammonium chlorides and alkyl
dimethylethyl benzyl ammonium chlorides.
[0066] Onserts and methods of applying them to the outside of
packages are disclosed in U.S. Pat. Pub. No. 2008/0128300 to Bahar
et al., U.S. Pat. No. 7,228,961 to Koettner et al., U.S. Pat. No.
7,174,938 to Cadieux et al., U.S. Pat. No. 6,681,927 to Focke et
al., U.S. Pat. No. 6,467,927 to Tallier et al., U.S. Pat. No.
5,250,134 to Thomas et al., and U.S. Pat. No. 2,011,399 to
Driscoll, which are each hereby incorporated by reference in their
entirety, and the present embodiments of the onsert 34 may be
applied in the same fashion, or in any other fashion known to those
skilled in the art. Alternatively, as shown in FIG. 15, the onsert
34 could be attached to the internal side 14 of the lid 12 of the
smokeless tobacco container 10 to minimize the increase in size of
the entire container 10.
[0067] In use, once a user is done with a pouch of a smokeless
tobacco product, the user can place the used pouch in the onsert 34
and seal it closed, either permanently or temporarily. The material
of the onsert 34 prevents the damp used pouch from staining a
user's pocket, and eliminates the immediate need to find a disposal
bin. Furthermore, the onsert 34 can be sized to accept the same
number of pouches that are provided in the smokeless tobacco
container 10.
[0068] Since many of the formats described are substantially flat
until used, multiple layers of the described onserts 34 could also
be applied such that when one layer is used, it could be removed
for disposal when convenient, and another layer is exposed for
subsequent use.
[0069] Moreover, the present onsert 34 could be utilized as a
cigarette butt disposal unit as well if it were to be attached to a
cigarette box. For example, the onserts 34 previously described
could be lined with aluminum foil so as to better inhibit stale
smoke smell from escaping the sealed onsert 34. Alternatively, the
papers and plastics used could be laminated to aluminum foil.
Alternatively, the plastic bag 60 previously described could be
replaced with aluminum foil.
[0070] Finally, the onsert 34 could take any shape or size
depending on the smokeless tobacco container 10 it is attached to,
and how much material it needs to hold. The onsert 34 could also
have printing or other designations on it to maximize its
usefulness so that the manufacturer does not give up valuable
advertising space on the outside of the smokeless tobacco container
10.
[0071] Referring to FIG. 1, there is shown an embodiment of a
smokeless tobacco product 18 that can be placed in the containers
described previously. The tobacco product 18 includes a
moisture-permeable pouch 78. The illustrated pouch 78 is sealed
closed along its length at an overlap region 82. The overlap region
may be formed by sealing the bottom portion of one edge of the
pouch 78 over the top portion of the opposite edge of the pouch
(e.g., by heat sealing, suitable adhesive, or other suitable
means). A solid tobacco material 80 is disposed within the pouch
82.
[0072] Suitable packets, pouches or containers of the type used for
the manufacture of smokeless tobacco products are available under
the trade names "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 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 78 and into the mouth of the user.
[0073] In certain embodiments, an exemplary pouch 78 may be
manufactured from materials, and in such a manner, such that during
use by the user, the pouch 78 undergoes a controlled dispersion or
dissolution. Such pouch materials may have the form of a mesh,
screen, perforated paper, permeable fabric, or the like. For
example, pouch material manufactured from a mesh-like form of rice
paper, or perforated rice paper, may dissolve in the mouth of the
user. As a result, the pouch 78 and tobacco formulation each may
undergo complete dispersion within the mouth of the user during
normal conditions of use, and hence the pouch 78 and tobacco
formulation both may be ingested by the user. Other exemplary pouch
materials may be manufactured using water dispersible film forming
materials (e.g., binding agents such as alginates,
carboxymethylcellulose, xanthan gum, pullulan, and the like), as
well as those materials in combination with materials such as
ground cellulosics (e.g., fine particle size wood pulp). Preferred
pouch materials, though water dispersible or dissolvable, may be
designed and manufactured such that under conditions of normal use,
a significant amount of the tobacco formulation contents permeate
through the pouch material prior to the time that the pouch
undergoes loss of its physical integrity. If desired, flavoring
ingredients, disintegration aids, and other desired components, may
be incorporated within, or applied to, the pouch material.
[0074] Descriptions of various components of snus products and
components thereof also are set forth in U.S. Pat. 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. 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 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. G.D SpA out of Italy also supplies
tobacco pouching equipment. 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) and can be 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.
[0075] The present invention also encompasses various additions and
modifications to the fleece material of the pouches. The fleece
materials used for the pouches are typically nonwoven materials.
Materials such as liquids, encapsulated products, or powders can be
incorporated into these nonwoven materials at various points during
their manufacture to accomplish many different purposes such as:
controlling the pH produced in the user's mouth upon insertion,
flavoring, reducing the initial sting of the tobacco product in the
mouth, coloring the fleece, or reducing discoloration of the
nonwoven material. Exemplary fleece materials include BFF's SDH27
Natural Grade and BFF's SDH27 Brown.
[0076] Nonwovens such as those used in tobacco containing fleece
pouches are textiles that are neither woven or knit. They are
generally made by extruding a polymeric material into continuous
filaments and then providing a type of bond such as meltblown,
spunbond or spunlaid. Typical synthetic polymers used in
manufacturing nonwovens are polypropylene and polyesters. Other
types of nonwoven materials are typically manufactured by chopping
the extruded filaments into small fibers to form a staple material,
and then combining them together to form a net or web which is then
bound in a various number of ways. For example, the fibers can be
bound mechanically, with an adhesive, or utilizing a binder
material. Two common nonwovens are staple nonwovens and spunlaid
nonwovens.
[0077] Staple nonwovens are made in two steps. The extruded fibers
are spun, cut to a few centimeters in length and baled. The bales
are dispersed on a conveyor belt and the fibers are spread in a
uniform web by a wetlaid, drylaid or airlaid process or by carding.
Staple nonwovens are then bound, typically by using resin or
thermal bonding.
[0078] Spunlaid nonwovens are made in one continuous process.
Fibers are spun and then directly dispersed into a web by
deflectors or can be directed with air streams. Spunlaid nonwovens
are bonded either by resin or thermally.
[0079] There are also other methods of manufacturing nonwovens such
as starting with films and fibrillate and serrating or
vacuum-forming them with patterned holes. These methods are
commonly known in the art.
[0080] Several bonding methods can also be used depending on the
type of nonwoven that is being manufactured. Thermal bonding
comprises applying heat to the nonwoven, and hydroentaglement
comprises mechanical intertwining of fibers by water jets.
Ultrasonic pattern bonding can also be utilized, and needlefelt
comprises mechanical intertwining of fibers by needles. Chemical
bonding is also possible using binders such as latex emulsion or
solution polymers to chemically join the fibers. Chemical bonding
can also be used with binder fibers or powders that soften and melt
to hold other non-melting fibers together. One type of cotton
staple nonwoven is treated with sodium hydroxide to shrink bond the
mat by causing the cellulose-based fibers to curl up and shrink
around each other. Finally, meltblown means that the nonwovens are
weakly bonded from the air attenuated fibers intertangling with
themselves during web formation as well as the temporary tackiness
when they are forming.
[0081] It is known that nonwoven substrate material can be produced
that can give off an aroma and/or a flavor, particularly when
moistened. Such a nonwoven substrate and a method for forming it is
set forth in U.S. patent application Ser. No. 10/219,111 to
Tharreau which is herein incorporated by reference in its entirety.
The nonwoven substrate of Tharreau is formed through a process
comprising a stage of thermal attachment of cyclodextrin particles
to the nonwoven substrate. The resulting product is able to give
off an aroma and/or a flavor when it is subsequently moistened with
water, or when placed in a user's mouth.
[0082] Many different additives, as described above, could be added
to the nonwoven during manufacture. For example, as set forth in
U.S. patent application Ser. No. 12/014,525, to Robinson et al.,
buffers are commonly used in snus formulations to maintain the pH
levels during shipping and storage without the need for
refrigeration. These buffers are typically added to the snus
tobacco formulation themselves, but in the present embodiment of
the invention, the buffer solution is also added directly to the
nonwoven pouch material during manufacture. In one embodiment of
the present method, the buffer solution is added to the polymer
material before extrusion of the fiber into filaments. In an
alternative embodiment, the extruded fibers are soaked in the
buffer solution after extrusion. It is typically added to the snus
formulation in an amount that is about 3-12% of the dry weight of
the snus formulation. As disclosed in U.S. patent application Ser.
No. 12/014,525, to Robinson et al., improved buffering
characteristics over time can be obtained by using 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.
[0083] This method can also be used to incorporate an analgesic
into the fleece material, such as oil of cloves, eugenol, or other
chemical compounds capable of providing analgesic effects. The
compounds can vary depending on whether the product was designed
for over the counter or prescription use. The use of such
analgesics in the pouch can reduce the initial sting that is
sometimes felt by a user upon insertion of the snus pouch into the
mouth.
[0084] Analgesics can include opioids and other medicaments such as
morphine, mepidine, dentanyl, sufentranil, alfentanil, aspirin,
acetaminophen, ibuprofen, indomethacine, naproxen, atrin, isocome,
midrin, axotal, firinal, phrenilin, ergot, and ergot derivatives
(wigraine, cafergot, ergostat, ergomar, dihydroergotamine),
imitrex, and ketoprofen. Such medicaments have been used in the
past in over-coated chewing gum formulations, as disclosed in U.S.
Pat. No. 6,773,716 to Ream et al., which is herein incorporated by
reference in its entirety. When an analgesic is incorporated into
the fleece, the analgesic loading levels are such that during use,
the analgesic is released into the saliva and absorbed through the
oral mucosa.
[0085] Effervescent substances can also be added to the snus
tobacco or directly to the fleece pouch to aid in absorption of
medicaments into the buccal cavity. See U.S. Pat. No. 6,974,590 to
Panther et al. Effervescent compositions have also been employed
for use as taste masking agents in dosage forms which are not
dissolved in water prior to administration. For example, U.S. Pat.
No. 4,639,368 to Niazi et al. describes a chewing gum containing a
medicament capable of absorption through the buccal cavity and
containing a taste masking amount of an effervescent.
[0086] More recently effervescents have been employed to obtain
rapid dissolution and/or dispersion of the medicament in the oral
cavity. See U.S. Pat. Nos. 5,178,878 and 5,223,264 to Wehling et
al. The effervescent tends to stimulate saliva production thereby
providing additional water to aid in further effervescent action.
These dosage forms give an agreeable presentation of the drug,
particularly for patients who have difficulty in swallowing tablets
or capsules. PCT Pub. No. WO 97/06786 to Johnson et al. describes
pre-gastric absorption of certain drugs using rapidly-disbursing
dosage forms. An example of adding an effervescent material to a
hydroentangled textile is disclosed in U.S. Pat. No. 7,381,667 to
Bergquist et al.
[0087] Another method to reduce bitterness in the products that is
encompassed by the present invention is to add citric acid to the
pouch. Citric acid can enhance the flavor notes of the product and
can reduce bitterness as well. Other methods of reducing bitterness
include the addition of propolis or eucalyptus to the pouch.
Furthermore, these materials can be added to the tobacco directly,
as disclosed in U.S. Pat. No. 6,668,839 to Williams. Alternatively,
the tobacco itself can be aged or ground in a specific manner to
remove bitterness. Fillers, sweeteners, and casing agents, as well
as other materials, can be used alone or in combination to obtain
the desired flavor and mouth feel for the user.
[0088] Another method for controlling the mouth feel and taste of a
snus or other smokeless tobacco product is to utilize so called
"miracle fruit" berries. These red berries form the tropical plant
called miracle fruit, Richadella dulcifica or Synsepalum
dulcificum, reduce the sour and bitter taste of acids and add sweet
and palatable taste. The miracle fruit berries contain a
taste-modifying glycoprotein, miraculin, which is comprised of 191
amino acids, includes carbohydrate residues and has a molecular
mass of 24,600 (Jrnl. of Bio. Chem. 1989, 264, 6655-6659). The
native miraculin protein is a tetramer held together by several
disulfide bridges. The taste modification is well established and
described in U.S. Pat. No. 3,849,555 to Harvey. Sources of the
fruit are found in Western Africa, as well as in Florida, USA. The
fruit and fruit extract are available commercially through various
suppliers. The isolated miraculin protein is also commercially
available, most likely purified via methodology described in U.S.
Pat. No. 5,886,155 to Armah et al.
[0089] Incorporation of miracle fruit, extract, or isolated
miraculin into "smokeless" tobacco articles such as snus is
accomplished by crushing and dehydrating the fruit to obtain an
extract, or using commercially available extract or isolated
protein (extracts). The extracts may be added directly to the
tobacco before processing, during processing, or cased onto a
finished "smokeless" tobacco product by embedding or coating the
snus fleece with the extracts. Miracle fruit may also be added to
other smokeless tobacco products such as rods, sticks, tubes and
other types as disclosed in U.S. Pat. Pub. No. 2008/0029110 to Dube
et al., which is herein incorporated by reference in its
entirety.
[0090] According to U.S. Pat. No. 3,681,087 to Johnson, the unit
dosage of miracle fruit extract is between 0.1 and 50 mg, with an
optimum inclusion for taste modification between 20 and 30 mg. In
regards to purified protein, it is currently unknown what inclusion
level would be required for the desired effect. Since the
taste-modification of miraculin is dependent upon an acidic
environment, the processing of tobacco would need to result in a
tobacco saliva solution possessing an acidic pH. Current
applications for snus processing require the addition of sodium
bicarbonate, which moves this pH towards basicity. This step would
be removed, though a bitter taste would be expected, however,
subsequently modified by miraculin inclusion. Fewer sweeteners
would need to be added to the smokeless product, as the bitter acid
taste of the tobacco constituents in the smokeless product would be
modified into a sweet taste in the presence of miraculin.
[0091] Mouth feel can also be controlled by controlling the way the
pouch allows elements to leech out of the pouch into a user's
mouth. The pouch can be constructed such that only certain areas of
the pouch are permeable, thus controlling the rate of absorption
through the buccal cavity.
[0092] Another method of controlling mouth feel in a snus tobacco
product is to incorporate a form of effervescence into either the
tobacco itself, or into the snus fleece pouch as previously
described.
[0093] Finally, a drawback to fleece snus pouches is that they tend
to stain and discolor over time. Another embodiment of the present
invention solves this problem by incorporating an additive, such as
ethylcellulose or nitrocellulose, to the nonwoven material.
Alternatively, the method can encompass rotogravure printing the
side of the pouch that comes into contact with the tobacco in this
fashion. The pouch could also be coated with akyl ketene dimer (CAS
#144245-85-2). Another method to retard discoloration is to use two
separate layers of fleece. The inside layer would retard the
transfer of colorants from the tobacco to the outside layer. The
inside layer could be made of lighter weight material since the
purpose is to act as a spacer to prevent contact of tobacco with
the outer layer, not add to the structural strength of the pouch.
The inside layer could also be made of different materials such as
lightweight, porous paper or a fine mesh.
[0094] A snus pouch could also be used to create a tea-type drink.
For example, a snus pouch such as those described above could be
soaked in an 8 ounce glass of hot or cold water. The pouch would be
allowed to soak or steep in the water for an amount of time so that
the tobacco flavor could leach into the water. The tobacco-flavored
beverage could than be enjoyed.
[0095] Another embodiment of the present invention encompasses
adding colorants such as dyes and inks to the nonwoven pouch
material to add luster or shine as well as to identify flavors. For
example, cinnamon flavored snus could have a red tinted pouch, and
mint flavored snus could be provided in a green tinted pouch. Other
flavors and corresponding colors are contemplated. The fleece could
also be printed with dissolvable materials to identify the type of
snus, such as "Camel" or the flavor, such as "mint." Additionally,
the inks and dyes could carry additional flavors or other
substances. Furthermore, polymers can be engineered to provide
certain characteristics such as solubility and degradability.
[0096] 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. Pub. Nos.
2007/0062549 to Holton, Jr. et al. and 2007/0186941 to Holton, Jr.
et al.; and U.S. patent 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. See, also U.S.
Pat. No. 6,834,654 to Williams.
[0097] 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.
[0098] 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. Pub. Nos.
2007/0062549 to Holton, Jr. et al., 2007/0186941 to Holton, Jr. et
al., and 2008/0029110 to Dube 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).
[0099] 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.
[0100] 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 %, generally is less than about 50 weight %, and often is
less than about 45 weight %. Certain types of tobacco formulations
have moisture contents, prior to use, of less than about 15 weight
%, frequently less than about 10 weight %, and often less than
about 5 weight %. For certain tobacco products, such as those
incorporating snus-type tobacco compositions, the moisture content
may exceed 20 weight %, and often may exceed 30 weight %. For
example, a representative snus-type product may possess a tobacco
composition exhibiting a moisture content of about 25 weight % to
about 50 weight %, preferably about 30 weight % to about 40 weight
%.
[0101] 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 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.
[0102] 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).
[0103] 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 3-12% 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.
[0104] If such a buffer is desired, water is added to a snus
tobacco blend to bring the formulation to about 35-36% moisture
content. Salt can be added at the level desired, for example at
1.5% of the dry weight of the snus formulation. The mixture is
pasteurized at about 212.degree. F. (100.degree. C.) for one hour.
The mixture is then brought up to between 50% and 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 bringing the pH from about
9-9.5. The snus is then heated at about 175-185.degree. F. until
the pH drops to about 8.0 to 8.3.
[0105] 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. These
buffer recipes can be added to the snus formulation as described
above, in an amount that is about 7-15% of the dry weight of the
snus formulation.
[0106] 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.
[0107] 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."
[0108] One exemplary snus-type product possesses about 1 g of a
tobacco formulation having a moisture content of about 35 weight %;
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 %; 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.
[0109] Snus pouching is typically performed as an automated,
fast-moving process utilizing machines that have been developed to
portion the tobacco without clumping or excessive drying. However,
clumping still commonly occurs in machines that utilize a single
feed screw in the tobacco feed hopper to move the tobacco into the
pouching machine. Examples of tobacco pouching machines are
disclosed in PCT Pub. No. WO 08/062302 to Boldrini and PCT Pub. No.
WO 08/56135 to Onno.
[0110] Equipment for packaging the snus formulations into the
pouches referenced above will be herein described with reference to
FIGS. 17-21. The figures illustrate the infeed and metering system
84 of a typical tobacco pouching machine manufactured by Merz
Verpackungsmaschinen GmbH with an inventive modification to improve
the tobacco flow through the feed hopper 86. The infeed and
metering system 84 typically comprises a feed hopper 86, a motor
88, a feed or "metering" screw 90 with corresponding pins 92, a
discharge hole 94 on a discharge side 96 of the feed hopper 86, and
a corresponding dosing bowl 98.
[0111] The feed hopper 86 includes first 104 and second 106 ends
with the discharge hole positioned on the side wall 108 of the
second end 104. The hopper 86 is typically about 5.5 inches wide at
the top 100 and about 2.25 inches wide at the bottom 102. The
overall height of the hopper 86 is about 11.75 inches and the
overall length of the hopper 86 is about 11.5 inches. These
dimensions are exemplary only, and other hopper sizes can be used
as known in the art. The hopper 86 is positioned so that it slopes
down from the first end 104 to the second end 106 to ensure that
tobacco 120 in the feed hopper 86 flows from the first end 104 to
the second end 106, or discharge side, of the feed hopper 86.
[0112] A feed screw 90 is positioned near the bottom 102 of the
feed hopper 86 such that it can freely rotate without the pins 92
coming into contact with the sides 108 or bottom 102 of the feed
hopper 86. The feed screw 90 extends laterally across the entire
bottom of the feed hopper 86, and has a shaft 110 extends out of
both the first end 104 of the feed hopper 86 and the discharge hole
94 of the feed hopper 86. A plurality of pins 92 extend from the
perimeter of the feed screw 90. On the end of the feed screw 90
opposite the end positioned at the discharge hole 94, the feed
screw 90 extends through an opening in the hopper 86 and interfaces
with a motor 114 through a gearbox 116. The motor 88 that powers
the feed screw 90 is typically a 0.18 kw motor and powers a gearbox
116 which provides a fixed rotational speed of about 120 RPM. Other
motors and gearboxes known in the art may also be used.
[0113] The feed screw 90 is typically about 2 inches in diameter,
and the pitch of the pins 92 extending from the feed screw 90 is
about 1 turn in 2 inches. The diameter of the feed screw 90 and the
pitch of the pins 92 can be adjusted accordingly as known in the
art. In operation, tobacco enters the feed hopper 86 at the top 100
and the rotation of the feed screw 90 along with the pitch of the
pins 92 moves the tobacco toward the discharge hole 94 into the
dosing bowl 98.
[0114] However, typical infeed and metering systems have inherent
problems that cause down time and reduce efficiency. Referring to
FIG. 20, a dead zone 118 typically occurs near the second end 106
of the feed hopper 86 as the tobacco 120 feeds through the feed
hopper 86 with the assistance of the feed screw 90. An operator has
to regularly stop the machine to unpack this dead zone 118 and push
the tobacco 120 back into the feed screw 90 in order to keep the
tobacco flow consistent. Furthermore, the tobacco 120 supplied to
the feed hopper 86 in traditional machines tends to build up and
cling to the side walls 108 of the feed hopper 86 because of its
high moisture content. This results in a "rat hole" 122 in an area
of the feed hopper 86 which starves the feed screw 90 and the
dosing bowl 98 downstream from the feed screw 90 as shown in FIG.
21. This also causes equipment down time.
[0115] The present invention comprises a modified infeed and
metering system 84 of a pouching machine such as illustrated in
FIGS. 17-21. The modified pouching machine of the present invention
includes an additional agitator screw 124 positioned above the feed
screw 90. The agitator screw 124 includes a plurality of pins 126
extending from its perimeter, and it conveys tobacco 120 in an
opposite or neutral direction from the feed screw 90 in order to
move the tobacco 120 away from the dead zone 118 and eliminate the
rat holes 122. The direction of the tobacco 120 as a result of the
feed screw 90 and the agitator screw 124 are shown by arrows A and
B respectively in FIG. 19.
[0116] The agitator screw 124 in preferably configured with as
large a diameter as possible, and is spaced so as not to interfere
with the feed screw 90. A preferred diameter for the agitator screw
124 is about three inches. Furthermore, the pitch of the agitator
screw pins 126 is neutral or opposite the pitch of the feed screw
pins 92. The agitator screw 124 includes a pulley system defined on
the shaft 128 nearest the motor 88 and gearbox 116. The wheel 130
of the pulley system has a band 132 extending around its
circumference. The agitator screw 124 is positioned through an
opening in the first end 104 of the feed hopper 86 such that the
band 132 is in contact with the outer diameter of the shaft 110 of
the feed screw 90. The band 132 is preferably made from a material
which provides enough friction so that when the feed screw 90
rotates, the wheel 130 rotates in the opposite direction of the
feed screw 90 and in turn rotates the agitator screw 124. The
ratios between the wheel 130 and the feed screw 90 diameter are
such that the agitator screw 124 rotates at around 192 RPM.
[0117] In operation, the agitator screw 124 preferably turns at a
faster rate than the feed screw 90. A preferred configuration is to
mechanically drive the agitator screw 124 at a 1:6 to 1 ratio. The
speed, direction of rotation and positioning of the agitator screw
124 versus the feed screw 90 breaks up the agglomerated tobacco
particles and prevents the formation of dead zones 118 and rat
holes 122. This results in a more efficient pouching process, as
the machinery does not have to be stopped regularly to be cleaned
out.
[0118] Optionally, a screen 136 can be positioned between the
agitator screw 124 and the feed screw 90 in order to further reduce
agglomerated particles and improve processing of the tobacco. A
preferred mesh size for such a screen is a #6 Tyler screen, but
other screens could be utilized as known in the art.
[0119] It should be noted that there could be a wide range of
changes made to the present embodiments without departing from the
scope of the claimed invention. It is therefore intended that the
foregoing detailed description be regarded as illustrative rather
than limiting, and that it be understood that it is the following
claims, including all equivalents, that are intended to define the
spirit and scope of this invention.
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