U.S. patent application number 12/638394 was filed with the patent office on 2011-06-16 for tobacco product and method for manufacture.
This patent application is currently assigned to R. J. Reynolds Tobacco Company. Invention is credited to Matthew William Benford, Luis R. Monsalud, JR., John Paul Mua.
Application Number | 20110139164 12/638394 |
Document ID | / |
Family ID | 44141521 |
Filed Date | 2011-06-16 |
United States Patent
Application |
20110139164 |
Kind Code |
A1 |
Mua; John Paul ; et
al. |
June 16, 2011 |
Tobacco Product And Method For Manufacture
Abstract
The tobacco products incorporate binder systems. The binder
systems possess or exhibit thermoplastic properties,
characteristics or behaviors. The binder system can incorporate at
least one type of binding agent that exhibits thermoplastic
properties (e.g., the binding agent can be composed of at least one
thermoplastic polymeric material). Additionally, the binder system
can incorporate ingredients or materials so as to provide a binding
agent that exhibits thermoplastic characteristics (e.g., the
binding agent can be composed of at least one thermoplastic binding
material in combination with a plasticizer). Tobacco products are
produced by contacting tobacco, together with other desired
ingredients, in the presence of a binder system, and forming (e.g.,
by extrusion) the resulting mixture into a shape. Of particular
interest are processing conditions that most preferably involve
exposing a tobacco formulation to a temperature of less than about
100.degree. C. during processing conditions (such as those
experienced during extrusion), that involve use of a binding agent
that can be employed in relatively low amounts, that involve use of
a binding agent that exhibits desirable thermoplastic behavior (and
hence can act to provide good physical integrity to the formed
tobacco product) at processing conditions of less than about
100.degree. C., and that involve the use of relatively low to
moderate amounts of liquid processing aids (e.g., water or other
liquid carriers).
Inventors: |
Mua; John Paul; (Advance,
NC) ; Benford; Matthew William; (Winston-Salem,
NC) ; Monsalud, JR.; Luis R.; (Kernersville,
NC) |
Assignee: |
R. J. Reynolds Tobacco
Company
Winston-Salem
NC
|
Family ID: |
44141521 |
Appl. No.: |
12/638394 |
Filed: |
December 15, 2009 |
Current U.S.
Class: |
131/111 ;
131/352 |
Current CPC
Class: |
A24B 15/14 20130101;
A24B 3/14 20130101; A24B 13/00 20130101 |
Class at
Publication: |
131/111 ;
131/352 |
International
Class: |
A24B 1/10 20060101
A24B001/10; A24B 15/00 20060101 A24B015/00 |
Claims
1. A tobacco product in a form suitable for insertion into the
mouth of a user comprising: tobacco and a thermoplastic binder
system, the amount of the thermoplastic binder system being present
in an amount less than about 30 weight percent of the dry weight of
the tobacco product.
2. The tobacco product of claim 1, wherein the thermoplastic binder
system incorporates at least one thermoplastic polymeric
material.
3. The tobacco product of claim 2, wherein the thermoplastic
polymeric material comprises an amount less than about 20 weight
percent of the dry weight of the tobacco product.
4. The tobacco product of claim 2, wherein the thermoplastic
polymeric material exhibits thermoplastic behavior at temperatures
less than about 100.degree. C.
5. The tobacco product of claim 1, wherein the thermoplastic binder
system incorporates at least one thermoplastic binding material and
at least one plasticizer.
6. The tobacco product of claim 4, wherein the plasticizer
comprises at least one of glycerin, propylene glycol or
polyethylene glycol.
7. The tobacco product of claim 2, wherein the thermoplastic
binding material exhibits thermoplastic behavior at temperatures
less than about 100.degree. C.
8. The tobacco product of claim 1, wherein the thermoplastic binder
system exhibits thermoplastic behavior at temperatures less than
about 100.degree. C.
9. A method for making a smokeless tobacco product comprising:
contacting tobacco material and thermoplastic binder system to
provide a mixture; subjecting the mixture to elevated temperature;
forming the mixture into a desired shape of a tobacco product; and
cooling the tobacco product.
10. The method of claim 9, whereby the thermoplastic binder system
incorporates at least one thermoplastic binding material and at
least one plasticizer.
11. The method of claim 9, whereby the thermoplastic binder system
incorporates at least one thermoplastic polymeric material.
12. The method of claim 11, whereby the thermoplastic polymeric
material comprise an amount less than about 20 weight percent of
the dry weight of the tobacco product.
13. The method of claim 9, whereby the mixture comprises less than
about 30 weight percent of the thermoplastic binder system, based
on a total dry weight of the tobacco product.
14. The method of claim 9, whereby the forming of the mixture
involves subjecting the mixture to a temperature of less than about
100.degree. C.
15. The method of claim 9 whereby during forming, the mixture
possesses a moisture content greater than about 5 weight percent,
based on a total weight of the tobacco product and moisture.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to products made or derived
from tobacco, or that otherwise incorporate tobacco, and that are
intended for human consumption.
BACKGROUND OF THE INVENTION
[0002] Cigarettes, cigars, and pipes are popular smoking articles
that employ tobacco in various forms. Such smoking articles are
used by heating or burning tobacco, and aerosol (e.g., smoke) may
be inhaled by the smoker. Tobacco may also 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. Nos. 1,376,586 to Schwartz; 3,696,917 to Levi; 4,513,756
to Pittman et al.; 4,528,993 to Sensabaugh, Jr. et al.; 4,624,269
to Story et al.; 4,987,907 to Townsend; 5,092,352 to Sprinkle, III
et al.; and 5,387,416 to White et al.; U.S. Pat. Appl. Pub. No.
2005/0244521 to Strickland et al.; PCT WO 04/095959 to Arnarp et
al.; PCT WO 05/063060 to Atchley et al.; PCT WO 05/004480 to
Engstrom; PCT WO 05/016036 to Bjorkholm; and PCT WO 05/041699 to
Quinter et al., each of which is incorporated herein by reference.
See also, for example, the types of smokeless tobacco formulations,
ingredients, and processing methodologies set forth in U.S. Pat.
Nos. 6,953,040 to Atchley et al. and 7,032,601 to Atchley et al.;
U.S. Pat. Appl. Pub. Nos. 2002/0162562 to Williams; 2002/0162563 to
Williams; 2003/0070687 to Atchley et al.; 2004/0020503 to Williams;
U.S. Pat. Appl. Pub. Nos. 2005/0178398 to Breskin et al.;
2006/0191548 to Strickland et al.; 2007/0062549 to Holton, Jr. et
al.; 2007/0186941 to Holton, Jr. et al.; 2007/0186942 to Strickland
et at; 2008/0029110 to Dube et al.; 2008/0029116 to Robinson et
al.; 2008/0029117 to Mua et al.; 2008/0173317 to Robinson et al.;
2008/0209586 to Neilsen et al.; 2009/0095313 to Fuisz and
2009/0293889 to Kumar et al.; and U.S. patent application Ser. No.
12/476,621, filed Jun. 2, 2009 to Chen et al.; each of which is
incorporated herein by reference.
[0004] One type of smokeless tobacco product is referred to as
"snuff." Snuff typically is formulated in "moist" or "dry" forms.
Representative types of moist 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. have
been 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 have been 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. See also, for example, Bryzgalov et al., 1N1800 Life
Cycle Assessment, Comparative Life Cycle Assessment of General
Loose and Portion Snus (2005). In addition, certain quality
standards associated with snus manufacture have been assembled as a
so-called GothiaTek standard.
[0005] It would be desirable to provide in an efficient and
effective mariner enjoyable forms of tobacco products, and to
provide processes for preparing formed or extruded types of tobacco
products.
SUMMARY OF THE INVENTION
[0006] The present invention relates to products made or derived
from tobacco, or that otherwise incorporate tobacco, and are
intended for human consumption. Of particular interest, are tobacco
products, compositions or formulations, and methods for providing,
producing or assembling those tobacco products, compositions or
formulations. Certain highly preferred tobacco products can be used
in a so-called smokeless form, and are formulated and/or formed so
as to be suitable for insertion into the mouth of the smokeless
tobacco user.
[0007] The tobacco products incorporate binder systems. As such,
tobacco materials (which can have various forms, and which can be
comprised of various types of tobacco), as well as other suitable
ingredients, are processed in the presence of a binder system
during production or assembly. Of particular interest is a binder
system that possesses or exhibits thermoplastic properties,
characteristics or behaviors. The binder system can incorporate at
least one type of binding agent that exhibits thermoplastic
properties, characteristics or behaviors (e.g., the binding agent
can be composed of at least one thermoplastic polymeric material).
Additionally, the binder system can incorporate ingredients or
materials so as to provide a binding agent that exhibits
thermoplastic characteristics (e.g., the binding agent can be
composed of at least one thermoplastic binding material in
combination with a plasticizer). In certain embodiments, the
thermoplastic binder system can be composed of at least one
thermoplastic polymer material and a thermoplastic binding material
in combination with at least one plasticizer. In certain highly
preferred embodiments, the amount of thermoplastic polymeric
material employed to produce a representative processed tobacco
product can be no more than about 20 percent of the final formed
product or formulation, on a dry weight basis. Thus, the present
invention in one regard relates to a tobacco product in a form
suitable for insertion into the mouth of a user, and comprises
tobacco and thermoplastic binder system, wherein the amount of
thermoplastic binder system being present in an amount less than
about 30 weight percent of the dry weight of the tobacco
product.
[0008] Certain preferred methods for providing, producing or
assembling those tobacco products involve contacting tobacco,
together with other desired ingredients, in the presence of a
binder system, and forming the resulting mixture into a shape. In
certain highly preferred embodiments, the method comprises process
steps that involve extruding (or otherwise physically forming, such
as by molding or casting) the mixture into the form of a strip, a
sheet, a rod, a tube, or other desired shape. The mixing of the
tobacco formulation involves contacting the tobacco being processed
with a binder system that exhibits thermoplastic properties. The
processing conditions associated with the production of the tobacco
product are controlled so as to efficiently and effectively provide
a tobacco product having desired physical and sensory
characteristics (e.g., by controlling the temperature and/or
pressure experienced by the mixture during processing conditions,
the moisture and/or other solvent content of the mixture being
processed, mixing conditions, or the like). Of particular interest
are processing conditions that most preferably involve exposing a
tobacco formulation to a temperature of less than about 100.degree.
C. during processing conditions (such as those experienced during
extrusion), that involve use of a binding agent that can be
employed in relatively low amounts, that involve use of a binding
agent that exhibits desirable thermoplastic behavior (and hence can
act to provide good physical integrity to the formed tobacco
product) at processing conditions of less than about 100.degree.
C., and that involve the use of relatively low to moderate amounts
of liquid processing aids (e.g., water or other liquid carriers).
Thus, the present invention in one regard relates to a method for
making a smokeless tobacco product comprising the steps of
contacting tobacco material and thermoplastic binder system to
provide a mixture; subjecting the mixture to elevated temperature;
forming the mixture into a desired shape of a tobacco product; and
cooling the tobacco product.
[0009] As will be realized by those of skill in the art, many
different embodiments of tobacco products, and methods of making or
assembling a tobacco product, are possible. Additional uses,
advantages, and features of the tobacco product and methods of its
manufacture are set forth in the illustrative embodiments in the
detailed description herein and will become more apparent to those
skilled in the art upon examination of the following.
DETAILED DESCRIPTION OF THE INVENTION
[0010] The products, compositions, formulations, and methods
described herein 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
be thorough and complete, and will fully convey the scope of the
invention to those skilled in the art. As used in this
specification and the claims, the singular forms "a," "an," and
"the" include plural referents unless the context clearly dictates
otherwise. Reference to "dry weight percent" or "dry weight basis"
refers to weight on the basis of dry ingredients (i.e., all
ingredients except water).
[0011] Tobaccos used as tobacco materials for the preparation of
tobacco products, compositions or formulations may vary. The
tobaccos may include types of tobaccos such as flue-cured tobacco,
burley tobacco, sun-cured tobacco (e.g., Oriental tobacco or Indian
Kurnool), Maryland tobacco, dark tobacco, dark-fired tobacco,
Indian air cured, dark air cured (e.g., passanda, cubano, jatin and
bezuki tobaccos) or light air cured (e.g., North Wisconsin and
galpoa tobaccos), and Rustica tobaccos, as well as other rare or
specialty tobaccos or even green or uncured 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. Nos. 4,660,577 to Sensabaugh, Jr.
et al.; 5,387,416 to White et al.; and 6,730,832 to Dominguez et
al., U.S. Patent Appl. Pub. Nos. 2006/0037623 to Lawrence, Jr. and
PCT WO 2008/103935 to Nielsen et al.; 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. Certain types of unusual or rare
tobaccos can be sun cured. Representative Oriental tobaccos include
katerini, prelip, komotini, xanthi and yambol tobaccos. Tobacco
compositions including dark air cured tobacco are set forth in U.S.
Patent Appl. Pub. No. 2008/0245377 to Marshall et al., which is
incorporated herein by reference.
[0012] Tobacco products may incorporate a single type of tobacco
(e.g., in a so-called "straight grade" form). For example, the
tobacco may be composed solely of flue-cured tobacco (e.g., all of
the tobacco may be composed, or derived from, either flue-cured
tobacco lamina or a mixture of flue-cured tobacco lamina and
flue-cured tobacco stem). Tobacco products also (though most
preferably) may have a so-called "blended" form. For example, the
tobacco products may include composed of a mixture of parts or
pieces of flue-cured, burley (e.g., Malawi burley tobacco) and
Oriental tobaccos (e.g., as tobacco composed of, or derived from,
tobacco lamina, or a mixture of tobacco lamina and tobacco stem).
For example, a representative blend may incorporate about 30 parts
to about 70 parts burley tobacco (e.g., lamina, or lamina and
stem), and about 30 parts to about 70 parts flue cured tobacco
(e.g., stem, lamina, or lamina and stem) on a dry weight basis.
Other exemplary tobacco blends incorporate on a dry weight basis
about 75 parts flue-cured tobacco, about 15 parts burley tobacco,
and about 10 parts Oriental tobacco; or about 65 parts flue-cured
tobacco, about 25 parts burley tobacco, and about 10 parts Oriental
tobacco; or about 65 parts flue-cured tobacco, about 10 parts
burley tobacco, and about 25 parts Oriental tobacco. Other
exemplary tobacco blends incorporate about 20 to about 30 parts
Oriental tobacco and about 70 to about 80 parts flue-cured tobacco.
The tobacco that is processed in accordance with the present
invention can have the form of previously processed tobacco parts
or pieces, cured and aged tobacco in essentially natural lamina or
stem form, tobacco extracts, 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, or a mixture that combines granulated
tobacco lamina and stems with an aqueous tobacco extract). Portions
of the tobaccos within the tobacco product may have processed
forms, such as processed tobacco stems (e.g., cut-rolled stems,
cut-rolled-expanded stems or cut-puffed stems), or volume expanded
tobacco (e.g., puffed tobacco, such as dry ice expanded tobacco
(DIET)). See, for example, the tobacco expansion processes set
forth in U.S. Pat. Nos. 4,340,073 to de la Burde et al.; 5,259,403
to Guy et al.; and 5,908,032 to Poindexter, et al.; and U.S. Patent
Appl. Pub. No. 2004/0182404 to Poindexter, et al., all of which are
incorporated by reference. In addition, the tobacco product
optionally may incorporate tobacco that has been fermented. See,
also, the types of tobacco processing techniques set forth in PCT
WO 05/063060 to Atchley et al., which is incorporated herein by
reference.
[0013] The tobacco that is processed most preferably includes
tobacco lamina, or tobacco lamina and stem mixture. Tobacco
mixtures incorporating a predominant amount of tobacco lamina,
relative to tobacco stem, are preferred. Most preferably, the
tobacco lamina and stem are used in an unextracted form, that is,
such that the extractable portion (e.g., the water soluble portion)
is present within the unextractable portion (e.g., the tobacco
pulp) in a manner comparable to that of natural tobacco provided in
a cured and aged form.
[0014] The tobacco that is processed can have a shredded, ground,
granulated, fine particulate, or powder form. The manner by which
the tobacco is provided in a finely divided or powder type of form
may vary. Preferably, tobacco parts or pieces are comminuted,
ground or pulverized into a powder type of form using equipment and
techniques for grinding, milling, or the like. Most preferably, the
tobacco is relatively dry in form during grinding or milling, using
equipment such as hammer mills, cutter heads, air control mills, or
the like. For example, tobacco parts or pieces may be ground or
milled when the moisture content thereof is less than about 15
weight percent to less than about 5 weight percent.
[0015] Most preferably, the tobacco that is processed can be
employed in the form of parts or pieces that have an average
particle size less than that of the parts or pieces of shredded
tobacco used in so-called "fine cut" tobacco products. Typically,
the very finely divided tobacco particles or pieces can be sized to
pass through a screen of about 18 Tyler mesh, generally can be
sized to pass a screen of about 20 Tyler mesh, often can be sized
to pass through a screen of about 50 Tyler mesh, frequently can be
sized to pass through a screen of about 60 Tyler mesh, may even be
sized to pass through a screen of 100 Tyler mesh, and further may
be sized so as to pass through a screen of 200 Tyler mesh. If
desired, air classification equipment may be used to ensure that
small sized tobacco particles of the desired sizes, or range of
sizes, may be collected. In one embodiment, the tobacco material is
in particulate form sized to pass through an 18 Tyler mesh, but not
through a 60 Tyler mesh. If desired, differently sized pieces of
granulated tobacco may be mixed together. In some products or
formulations, very finely divided tobacco particles or pieces have
a particle size greater than -8 Tyler mesh, often -8 to +100 Tyler
mesh, frequently -18 to +60 Tyler mesh. In other products or
formulations, very finely divided tobacco particles or powders
suitable for smokeless products described herein can have a
particle size less than -8 Tyler mesh, often +100 to +250 Tyler
mesh, and frequently +120 to +280 Tyler mesh.
[0016] Tobacco extracts may be used as components of the tobacco
product. A tobacco extract can be used in solid form (e.g.,
spray-dried or freeze-dried form), in liquid form, in semi-solid
form, or the like. Exemplary tobacco extracts and extraction
techniques are set forth, for example, in U.S. Pat. Nos. 4,150,677
to Osborne, Jr. et al.; 4,967,771 to Fagg et al.; 5,005,593 to Fagg
et al.; 5,148,819 to Fagg; and 5,435,325 to Clapp et al., all of
which are incorporated by reference herein. Various tobacco
extraction and reconstitution methodologies are set forth in U.S.
Pat. Nos. 5,065,775 to Fagg; 5,360,022 to Newton; and 5,131,414 to
Fagg, all of which are incorporated by reference herein. See also,
the tobacco extract treatment methodologies set forth in U.S. Pat.
Nos. 5,131,415 to Munoz et al. and 5,318,050 to Gonzalez-Parra,
both of which are incorporated by reference herein.
[0017] The tobacco materials that are processed optionally can
incorporate reconstituted tobaccos, and as such, tobacco
formulations that are processed can be absent of reconstituted
tobacco ingredient components. However, suitable known
reconstituted tobacco processing techniques, such as paper-making
techniques or casting-type processes, can be employed to provide
such optional tobacco ingredient components. See, for example, the
types of paper-making processes set forth in U.S. Pat. Nos.
3,398,754 to Tughan; 3,847,164 to Mattina; 4,131,117 to Kite;
4,270,552 to Jenkins; 4,308,877 to Mattina; 4,341,228 to Keritsis;
4,421,126 to Gellatly; 4,706,692 to Gellatly; 4,962,774 to
Thomasson; 4,941,484 to Clapp; 4,987,906 to Young; 5,056,537 to
Brown; 5,143,097 to Sohn; 5,159,942 to Brinkley et al.; 5,325,877
to Young; 5,445,169 to Brinkley; 5,501,237 to Young; 5,533,530 to
Young; which are incorporated herein by reference. See, for
example, the casting processes set forth in U.S. Pat. Nos.
3,353,541 to Hind; 3,399,454 to Hind; 3,483,874 to Hind; 3,760,815
to Deszyck; 4,674,519 to Keritsis; 4,972,854 to Kiernan; 5,023,354
to Hickle; 5,099,864 to Young; 5,101,839 to Jakob; 5,203,354 to
Hickle; 5,327,917 to Lekwauwa; 5,339,838 to Young; 5,598,868 to
Jakob; 5,715,844 to Young; 5,724,998 to Gellatly; and 6,216,706 to
Kumar; and EPO 565360; EPO 1055375 and PCT WO 98/01233; which are
incorporated herein by reference.
[0018] If desired, prior to preparation of the tobacco product, the
parts or pieces of tobacco material 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 a tobacco 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 ingredients and
other additional components may be incorporated within the
formulation. Alternatively, the tobacco product can be irradiated
or pasteurized after the tobacco formulation has been processed
(e.g., after an extruded tobacco product is formed, or after
extruded product is sub-divided into a desired size and
incorporated within a moisture-permeable packet or pouch so as to
provide individual containers of snus-type smokeless tobacco
product).
[0019] The tobacco materials also can be subject to other types of
pre-treatment conditions prior to being used in the process steps
of the present invention. For example, the tobacco materials can be
treated to alter the physical or sensory characteristics of the of
the tobacco material. In one regard, the tobacco material can be
moistened or reordered. In another regard, the tobacco material can
be pre-treated by treatment involving the application of heat,
steam, cooking, or the like. In another regard, various additional
components, such as those of the type set forth hereinafter, can be
combined with the tobacco material during pre-treatment processing
conditions (e.g., such as conditions involving heat treatment). In
yet another regard, the tobacco material can be subjected to
treatment processes involving the use of materials having acidic or
basic characteristics. In still another regard, the tobacco
material can be treated in the manner set forth in U.S. patent
application Ser. No. 12/476,621, filed Jun. 2, 2009 to Chen et al.;
each of which is incorporated herein by reference.
[0020] The tobacco materials that are processed can be processed in
combination with at least one additional component. For example,
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, buffering agents, 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 U.S. Pat. No. 5,387,416 to White et al.; U.S.
Pat. App. Pub. Nos. 2005/0244521 to Strickland et al.; 2008/0029110
to Dube et al.; 2009/0293889 to Kumar et al.; U.S. patent
application Ser. No. 12/476,621, filed Jun. 2, 2009 to Chen et al.;
and PCT WO 05/041699 to Quinter et al., each of which is
incorporated herein by reference.
[0021] The sensory attributes of smokeless tobacco can also be
enhanced by incorporation of certain flavoring materials. Exemplary
flavoring agents or flavorants that can be used are components, or
suitable combinations of those components, that act to alter the
bitterness, sweetness, sourness, or saltiness of the smokeless
tobacco product, enhance the perceived dryness or moistness of the
formulation, or the degree of tobacco taste exhibited by the
formulation. Types of flavoring agents include salts (e.g., sodium
chloride, potassium chloride, sodium citrate, potassium citrate,
sodium acetate, potassium acetate, and the like), natural
sweeteners (e.g., fructose, sucrose, glucose, maltose, mannose,
galactose, lactose, and the like), artificial sweeteners (e.g.,
sucralose, saccharin, aspartame, acesulfame K, neotame, and the
like); and mixtures thereof. Flavoring agents may be natural or
synthetic, and the character of these flavors imparted thereby may
be described, without limitation, as fresh, sweet, herbal,
confectionary, floral, fruity or spice. Specific types of flavors
include, but are not limited to, vanilla, coffee, chocolate/cocoa,
cream, mint, spearmint, menthol, peppermint, wintergreen,
eucalyptus, lavender, cardamon, nutmeg, cinnamon, clove,
cascarilla, sandalwood, honey, jasmine, ginger, anise, sage,
licorice, lemon, orange, apple, peach, lime, cherry, strawberry,
and any combinations thereof. See also, for example, Leffingwell et
al., Tobacco Flavoring for Smoking Products, R. J. Reynolds Tobacco
Company (1972), U.S. Pat. Appl. Pub. Nos. 2002/0162562 to Williams;
2002/0162563 to Williams; 2003/0070687 to Atchley et al.;
2004/0020503 to Williams, 2005/0178398 to Breslin et al.;
2006/0191548 to Strickland et al.; 2007/0062549 to Holton, Jr. et
al.; 2007/0186941 to Holton, Jr. et al.; 2007/0186942 to Strickland
et al.; 2008/0029110 to Dube et al.; 2008/0029116 to Robinson et
al.; 2008/0029117 to Mua et al.; 2008/0173317 to Robinson et al.;
and 2008/0209586 to Neilsen et al., each of which is incorporated
herein by reference. The amount of flavoring agents utilized within
the tobacco product can vary, but is typically up to about 10 dry
weight percent, and certain embodiments are characterized by a
total flavoring agent content of at least about 1 dry weight
percent, such as about 1 to about 10 dry weight percent.
Combinations of flavorants are often may be used (e.g., about 0.1
to about 2 dry weight percent of an artificial sweetener and about
0.5 to about 8 dry weight percent of sodium chloride, based on the
total dry weight of the tobacco product).
[0022] Exemplary filler materials include vegetable fiber materials
such as sugar beet fiber materials (e.g., FIBREX.RTM. brand filler
available from International Fiber Corporation), oats or other
cereal grain (including processed or puffed grains), bran fibers,
starch, or other modified or natural cellulosic materials such as
microcrystalline cellulose. Additional specific examples include
corn starch, maltodextrin, dextrose, calcium carbonate, calcium
phosphate, lactose, manitol, xylitol, and sorbitol. An example of a
commercially available maltrodextrin that can be used is Maltrin 10
DE available from Corn Products International. The amount of filler
utilized in the tobacco composition or formulation can vary, but
can be typically up to about 60 dry weight percent, and certain
embodiments are characterized by a filler content of at least about
10 dry weight percent, such as about 20 to about 50 dry weight
percent. Combinations of fillers may be used (e.g., a mixture
composed of about 2 to about 8 dry weight percent of calcium
carbonate, about 10 to about 20 dry weight percent of rice flour,
and about 10 to about 20 dry weight percent of maltodextrin, based
on the total dry weight of the tobacco product).
[0023] Preferred pH adjusters or buffering agents provide and/or
buffer within a pH range of about 6 to about 10, and exemplary pH
adjusting or buffering agents include metal hydroxides, metal
carbonates, metal bicarbonates, and mixtures thereof. Specific
exemplary materials include sodium hydroxide, potassium hydroxide,
potassium carbonate, sodium carbonate, and sodium bicarbonate. The
amount of pH adjuster or buffering agent utilized in the tobacco
formulation can vary, but is typically at least about 0.05 dry
weight percent, but up to about 5 dry weight percent, based on the
total dry weight of the tobacco product. An exemplary amount of pH
adjuster or buffering agent is about 1 to about 5 dry weight
percent, based on the total weight of the tobacco product.
[0024] Exemplary colorants include various dyes and pigments. For
example, suitable colorants can include caramel coloring, titanium
dioxide, beta carotene, blackcurrant, annatto, grape skin,
canthaxanthin, carrot powders or extracts, or the like. The amount
of colorant utilized in the tobacco formulation can vary, but is
typically at least about 0.1 dry weight percent, but up to about 5
dry weight percent, based on the total dry weight of the tobacco
product. An exemplary amount of colorant is about 0.5 to about 3
dry weight percent, based on the total weight of the tobacco
product.
[0025] Other ingredients such as preservatives (e.g., potassium or
sodium sorbate, benzoate, propionate, sulfites, diacetate,
parabens, and menthol), disintegration aids (e.g., microcrystalline
cellulose, croscarmellose sodium, crospovidone, sodium starch
glycolate, pregelatinized corn starch, and the like), or
anti-sticking agents (e.g., exemplary commercially available
product of Confecto.TM. No-Stick `N`.TM. sold by International
Foodcraft Corporation) can also be used. Typically, such
ingredients individually are used in amounts of up to about 10 dry
weight percent, and usually at least about 0.1 dry weight percent,
such as about 0.5 to about 10 dry weight percent, based on the
total dry weight of the tobacco product.
[0026] The tobacco product incorporates a binder system, and the
binder system incorporates at least one type of binding agent that
exhibits thermoplastic properties, characteristics, or behaviors
(e.g., the binding agent can be composed of at least one
thermoplastic polymeric material). As such, a thermoplastic binder
system can incorporate ingredients or materials so as to provide a
binding agent that exhibits thermoplastic characteristics (e.g.,
the binding agent can be composed of at least one thermoplastic
polymeric material and/or at least one thermoplastic binding
material in combination with a plasticizing agent). The amount of
thermoplastic binder system material employed within a
representative processed tobacco product typically is at least
about 5 percent, and often at least about 10 percent, of the final
formed product, on a dry weight basis. The amount of thermoplastic
binder system material employed within a representative processed
tobacco product generally is less than about 40 percent, frequently
is less than about 35 percent, often less than about 30 percent,
and sometimes less than about 25 percent of the final formed
product, on a dry weight basis.
[0027] The ingredient materials of the thermoplastic binder system
can vary. The term thermoplastic as used herein refers to a
property of an ingredient (e.g., a polymeric material) where upon
heating, the ingredient softens or melts into a liquid that when
cooled, hardens or forms a gel. For example, a polymeric material
that comprises thermoplastic properties, characteristics or
behaviors softens or melts when exposed to heat, and then returns
to its original physical type of condition when cooled (e.g., to
about ambient temperature). As such, a thermoplastic binding agent
can be contacted with a tobacco material and various other
ingredients, mixed so as to provide physical contact of the binding
agent with those ingredients, heated so as to soften or liquefy the
polymeric material of the thermoplastic binder system, and then
cooled so as to harden the softened thermoplastic polymeric
material (and hence result in a tobacco product that is formed from
the ingredients and that has a desirable physical integrity). For
purposes of the present invention, desirable thermoplastic
polymeric materials generally soften or melt (and hence exhibit
thermoplastic characteristics) at temperatures in excess of about
50.degree. C., often in excess of about 60.degree. C., and
frequently in excess of about 70.degree. C.
[0028] Examples of representative suitable thermoplastic polymeric
materials include hydroxypropyl cellulose, polyethylene oxide,
certain cellulose ethers (e.g. ethylcellulose and hydroxypropyl
methylcellulose), polyvinyl alcohol and polyvinyl acetate. Examples
of commercially available hydroxypropyl cellulose include
KLUCEL.RTM. EF, ELF, and LF hydroxypropyl cellulose (HPC) sold by
Hercules Incorporated, Aqualon Division. Examples of commercially
available polyethylene oxide include Polyox N10 sold by The Dow
Chemical Company. Examples of commercially available ethylcellulose
include those available from Ronas Chemicals Ind. Examples of
commercially available hydroxypropyl methylcellulose that can be
used include Methocel.TM. E 50 sold by Hercules Incorporated,
Aqualon Division. Examples of commercially available polyvinyl
alcohol include Elvanol sold by E.I. DuPont de Nemours. Examples of
commercially available polyvinyl acetate include Elvacet sold by
E.I. DuPont de Nemours. See also, for example, the types of
thermoplastic polymers, such as polymethyl acrylate, set forth in
U.S. Patent Publication No. 2009/0095313 to Fuisz, which is
incorporated by reference. Typical thermoplastic polymeric
materials exhibit thermoplastic characteristics at temperatures
below about 140.degree. C., and more preferably below about
120.degree. C. Highly preferred thermoplastic polymeric materials
exhibit thermoplastic characteristics at temperatures below about
100.degree. C., and most preferably below about 90.degree. C.
[0029] The amount of thermoplastic polymeric materials employed
within a representative processed tobacco product typically is at
least about 5 percent, and often at least about 10 percent, of the
final formed product, on a dry weight basis. The amount of
thermoplastic polymeric material employed within a representative
processed tobacco product generally is less than about 30 percent,
frequently is less than about 25 percent, typically less than about
20 percent, and often less than about 15 percent of the final
formed product, on a dry weight basis.
[0030] The binder system can incorporate a compound that can be
characterized as a plasticizer. For example, the aforementioned
thermoplastic binding materials can be combined with, and
processing in the combination with, at least one plasticizer.
Highly preferred plasticizers are organic non-polymeric materials,
and exemplary representative plasticizers include glycerin,
propylene glycol, polyethylene glycol, and combinations thereof.
Certain plasticizers can be provided by various polyols, such as
medium and high molecular weight polyol-type compounds. The amount
of plasticizer utilized within the tobacco product can vary. When
employed, the amount of plasticizer employed within a
representative processed tobacco product typically is at least
about 1 percent, often at least about 2 percent, and frequently at
least about 3 percent, of the final formed product, on a dry weight
basis. When employed, the amount of plasticizer employed within a
representative processed tobacco product typically is up to about
15 percent, often up to about 10 percent, and frequently up to
about 5 percent, of the final formed product, on a dry weight
basis.
[0031] Typically, the selection and amount of plasticizer are such
that there is provided a lowering in the softening temperature of
the thermoplastic binding material. The plasticizer can act to
facilitate hydration, and hence facilitate liquification of
thermoplastic binding material. As such, formation of the tobacco
product at relatively low temperatures can be facilitated. In this
way, the binder system within a tobacco formulation can lower the
operating temperature at which the tobacco formulation is formed
thereby reducing and/or avoiding the scalding and/or charring of
the tobacco materials. In addition, the plasticizer reduces the
need for large amounts of moisture, or other liquid carrier
materials, that in turn need to be boiled off through drying stages
after formation of the tobacco product. For example, for tobacco
formulations incorporating thermoplastic binding material, liquid
(e.g., water) and plasticizer, there can be provided a formulation
suitable for extrusion of a desirable tobacco product, at
temperatures typically lower than that of the normal melting point
of the thermoplastic binding material.
[0032] Highly preferred thermoplastic binding materials that can be
suitably employed in combination with at least one plasticizer can
vary. Examples of such types representative thermoplastic binding
materials include polyvinyl polypyrrolidone, methylcellulose,
xanthan, gum arabic, maltodextrin, pullulan, certain modified
starches and high molecular weight propylene glycols (e.g.,
propylene glycols having molecular weights above about 4000).
Examples of commercially available polyvinyl polypyrrolidone that
can be used include Plasdone.RTM. K-29/32 sold by FMC BioPolymer.
Examples of commercially available methylcellulose that can be used
include the Methocel Series of polymeric materials sold by Hercules
Inc., Aqualon Division. Examples of commercially available xanthan
and gum arabic that can be used include those available from TIC
Gums. Examples of commercially available maltodextrin that can be
used include Maltrin 10 DE available from Grain Processing Corp.
Examples of suitable commercially available modified starches
include Elastigel.TM. 1000J and INSTANT TEXTAID.RTM.-A sold by
National Starch and Chemical Company. Examples of suitable high
molecular weight propylene glycol that can be used include PEG 4000
sold by The Dow Chemical Company. Suitable pullulan materials are
set forth in US Pat. Appl. Pub. No. 2007/0246055 to Borschke, et
al., which is incorporated herein by reference. When employed in
conjunction with effective amounts of plasticizer, such types of
thermoplastic binding materials typically exhibit thermoplastic
characteristics at temperatures below about 140.degree. C., and
more preferably below about 120.degree. C. Highly preferred
thermoplastic binding materials exhibit thermoplastic
characteristics at temperatures below about 100.degree. C. These
types of thermoplastic binding materials that can be suitably
employed in combination with the aforementioned plasticizer can be
employed with thermoplastic polymeric materials, and in some cases
in the absence of a plasticizer.
[0033] The amount of thermoplastic binding materials employed
within a representative processed tobacco product typically can be
at least about 5 percent, and often at least about 10 percent, of
the final formed product, on a dry weight basis. The amount of
thermoplastic binding material employed within a representative
processed tobacco product generally can be less than about 30
percent, frequently is less than about 25 percent, typically less
than about 20 percent, and often less than about 15 percent of the
final formed product, on a dry weight basis.
[0034] Thermoplastic polymeric materials, thermoplastic binding
materials employed in combination with a plasticizer, and mixtures
of these materials can be processed at the processing and operating
conditions of the present invention described herein. Such
thermoplastic polymeric materials, thermoplastic binding materials
employed in combination with a plasticizer, and mixtures of these
materials typically exhibit thermoplastic characteristics at
temperatures below about 140.degree. C., and more preferably below
about 120.degree. C. Highly preferred thermoplastic polymeric
materials, thermoplastic binding materials employed in combination
with a plasticizer, and mixtures of these materials employed in
combination with a plasticizer exhibit thermoplastic
characteristics at temperatures below about 100.degree. C.
[0035] The thermoplastic binder systems can be employed in
conjunction with other binding agents. Typical of such other types
of binding agents are those that include, but are not limited to,
carboxymethyl cellulose and certain other modified cellulosic
materials, alginates such as sodium alginate, certain starch-based
binders, pectins, carrageenan, zein, and the like. These types of
binding agents may not substantially exhibit thermoplastic behavior
or characteristics under the conditions and processes of the
present invention. One exemplary carboxymethyl cellulose is
commercially available as Ac-Di-Sol.RTM. sold by FMC BioPolymer.
Examples of suitable alginates that include Algin 400 sold by TIC
Gums and the Manucol types alginates sold by FMC Biopolymers.
Examples of suitable starch-based binders include pre-gelatinized
rice starches. Examples of suitable pectins and carrageenans are
available from TIC Gums and FMC Biopolymers. Examples of suitable
zein that are available from Alfa Chemicals. The amount of the
other optional binding agent employed typically is less than about
20 percent, and often less than about 15 percent, and frequently is
less than about 10 percent, of the final formed product, on a dry
weight basis. When employed, the amount of the other optional
binding agent that employed typically is at least about 1 percent,
and often at least about 3 percent, and frequently at least about 5
percent, of the final formed product, on a dry weight basis. In
certain systems, these optional binding agents may require
additional moisture when employed in a tobacco product.
[0036] The manner by which the various components of the tobacco
formulation can be combined may vary. The various components of the
formulation may be contacted, combined, or mixed together in
conical-type blenders, mixing drums, ribbon blenders, or the like.
As such, the overall mixture of various components with the
granulated tobacco components, and other ingredients, may be
relatively uniform in nature. See also, for example, the types of
methodologies set forth in U.S. Pat. No. 4,148,325 to Solomon et
al.; U.S. Pat. No. 6,510,855 to Korte et al.; and U.S. Pat. No.
6,834,654 to Williams, each of which is incorporated herein by
reference. The components of the tobacco formulation can be brought
together in admixture using any mixing technique or equipment known
in the art. The components noted herein, which may be in liquid or
dry solid form, can be admixed with the tobacco in a pretreatment
step prior to mixture with any remaining components of the
composition or simply mixed with the tobacco together with all
other liquid or dry ingredients. Any mixing method that brings the
tobacco composition ingredients into intimate contact can be used.
A mixing apparatus featuring an impeller or other structure capable
of agitation is typically used. Exemplary mixing equipment includes
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.
[0037] Components of the tobacco formulation also can be provided
by liquid materials or ingredients. The liquid ingredients can be
provided in a variety of ways, and can be provided from a variety
of sources. The tobacco formulation can be moist, and moisture can
be provided by aqueous liquid supplied as such, as moist tobacco,
or as a carrier liquid for ingredients of the tobacco formulation.
Other liquid ingredients, such as organic solvents (e.g., ethanol),
can be carrier liquids for certain ingredients of the tobacco
formulation. The plasticizers of the thermoplastic binder system
also typically have a liquid form.
[0038] The tobacco formulation, when processed, can have a
relatively low to moderate moisture content. The moisture content
of the tobacco formulation during processing steps typically can
exceed about 5 percent, frequently can exceed about 10 percent, and
often can exceed about 15 percent, based on the total weight of the
tobacco formulation and water. The moisture content of the tobacco
formulation during processing steps typically can is less than
about 35 percent, frequently is less than about 30 percent, and
often is less than about 25 percent, based on the total weight of
the tobacco formulation and water.
[0039] The manner that the tobacco product is formed can vary, and
various methods for forming processed tobaccos or for producing
processed tobacco products will be readily apparent to those
skilled in the art of tobacco product manufacture. For example,
suitably heated tobacco formulations incorporating thermoplastic
binder systems and having a pourable, formable or generally liquid
character can be cast into a sheet-like form and cooled to yield a
sheet-like tobacco product of good integrity. As another example,
suitably heated tobacco formulations incorporating thermoplastic
binder systems can be molded into a desired shape and cooled. As
yet another, but preferred, example, tobacco formulations
incorporating thermoplastic binder systems can be extruded from
heated extrusion devices and cooled.
[0040] The tobacco product can be manufactured using hot melt
extrusion techniques. As such, processed tobacco formulations can
be subjected to sufficient heat during formation of tobacco product
to eliminate the need for any additional heat treatment steps. For
example, flashing off the moisture from a processed tobacco
formulation during a hot melt extrusion process can eliminate any
need for further heating, drying, or the like.
[0041] Processed tobacco formulations, 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 twin
screw extruders). 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 plasticizers (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. Multilayered materials can have the general
form of films, and alternatively, multi-layered generally spherical
materials can possess various layers extending from the inside
outward.
[0042] Some shapes of smokeless tobacco products, such as rods or
cubes, can be formed by first extruding the material through a die
having the desired cross-section (e.g., round or square) and then
optionally cutting the extruded material into desired lengths. For
example, extruder equipment comprising single or multiple screw
extruders can by employed to form the shape of a smokeless tobacco
product. Some extruders can comprise twin screw extruders which
comprise co-rotating twin screw extruders. Various screw
configurations can be employed. For example, screws having
combinations of elements for feeding, mixing, pumping, shearing,
and the like, can be selected as desired for optimum results.
Screws having sections or elements which provide relatively large
output capacities, which have interrupted or nonconjugated flights,
or which are "counterflighted" or "reversing" also can be employed.
Typical screw elements as well as screws having combinations of
such elements are available from extruder manufacturers. An
extruder can provide a barrel for heating of the materials which
are introduced within the extruder. The conditions of the extrusion
set-up can vary, for example, in modifying feed rate of dry blend
ingredients, feed rate of wet blend ingredients, screw RPM setting,
temperature conditions, aperture die dimensions, as well as
additional parameters.
[0043] Techniques and equipment for extruding tobacco materials
have been set forth in U.S. Pat. Nos. 3,098,492 to Wursburg;
4,874,000 to Tamol et al.; 4,880,018 to Graves et al.; 4,989,620 to
Keritsis et al.; 5,072,744 to Luke et al.; 5,829,453 to White et
al.; and 6,182,670 to White et al.; each of which is incorporated
herein by reference. Exemplary extrusion equipment suitable for use
include industrial pasta extruders such as Model TP 200/300
available from Emiliomiti, LLC of Italy.
[0044] Processed sheet-like materials can be prepared by applying
the tobacco composition onto a moving belt and passing the moving
belt through a nip formed by opposing rollers, followed by cutting
the sheet into desired lengths. Alternatively, the tobacco product
can be over-coated with powdered or liquid coating. Furthermore, if
desired, the surface of the tobacco product can be embossed or
printed.
[0045] The pH of the tobacco product 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 the tobacco product will not exceed
about 10, and often will not exceed about 9.5. A representative
tobacco product exhibits a pH of about 6.8 to about 8.2. A
representative technique for determining the pH of a tobacco
product involves dispersing 5 g of that product in 100 mL of
deionized water, and measuring the pH of the resulting
suspension/solution (e.g., with a pH meter).
[0046] The relative amount of tobacco employed in combination with
the additional components and binding system components can vary.
The amount of tobacco material within the tobacco product typically
is at least about 10 percent, generally at least about 25 percent,
often at least about 30 percent, and frequently at least about 35
percent, on a dry weight basis, based on the total dry weight of
the processed formulation or final product. In certain instances,
the amounts of other components and binding system components
within the tobacco formulation may exceed about 40 percent, on a
dry weight basis. A typical range of tobacco material within the
formulation is about 10 to about 60 weight percent, more often
about 20 to about 40 weight percent, on a dry basis.
[0047] The moisture content of the tobacco product prior to use by
a consumer of the product may vary. Typically, the moisture content
of the tobacco product, such as tobacco formulation within a
snus-type 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 products 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. A tobacco product can comprise a moisture content prior to
use in the range of about 5 weight percent to about 15 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. For yet other tobacco products,
such as those in a stick form, the tobacco product can comprise a
moisture content of about 5 weight percent to about 15 weight
percent.
[0048] Exemplary shapes of formed tobacco products include pill,
tablet, sphere, sheet, film, coin, cube, bead, ovoid, obloid, bean,
stick, and rod. Tobacco products of the present invention can be
used as smokeless tobacco compositions, such as loose moist snuff,
loose dry snuff, chewing tobacco, pelletized tobacco pieces,
compressed tobacco pieces, molded processed tobacco pieces,
extruded or formed tobacco strips, pieces, rods or sticks, finely
divided ground powders, finely divided or milled agglomerates of
powdered pieces and components, flake-like pieces, pieces of
tobacco-containing gum, rolls of tape-like films, readily
water-dissolvable or water-dispersible films or strips (see, for
example, U.S. Pat. Appl. Pub. No. 2006/0198873 to Chan et al. and
U.S. Pat. Appl. Pub. No. 2009/0095313 to Fuisz), extruded or formed
sticks or rods, extruded or molded tubes, layered or laminated
materials (e.g., multi-layered compositions having one type of
tobacco formulation surrounded by a different type of tobacco
formulation), 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 Newtonian fluid or a
thixotropic fluid incorporating tobacco of some form). As an
example, pieces of extruded sheets or films can be wrapped around
formed tobacco-containing pieces. As yet another example, extruded
pieces can be sub-divided into small pieces and incorporated with
other tobacco materials within snu-type pouches. A preferred form
of a tobacco product is a product having the form of an extruded
piece or pieces composed of tobacco material and other ingredients
held together using a binder system. Such extruded pieces also may
be processed or further sub-divided into formed pieces. For
example, extruded tobacco compositions can be roll pressed or
otherwise physically treated; and then rolled into a roll for
storage and later use, or cut into the desired shape for packaging
and use.
[0049] Tobacco products incorporating thermoplastic binder systems
offer several advantages. In one regard, the binder system allows
for efficient and effective extrusion of a tobacco product (e.g.,
tobacco product can be produced at a desired throughput). In
another regard, extrusion of a tobacco formulation can be carried
out at relatively low temperatures; and as such the tobacco
formulation can be processed using reduced amounts of energy and
under conditions that reduce the chances of scalding or charring
the tobacco material during processing. In yet another regard,
tobacco products possessing reduced amounts of binding agent can be
provided, hence increasing the relative amount of tobacco and
flavoring agent within the tobacco product and thereby enhancing
the sensory characteristics of those products.
[0050] The incorporation of the binder system into a tobacco
product according to methods described herein can provide improved
user satisfaction upon use of the tobacco product as compared to a
tobacco product relying upon a thermoplastic polymer in relatively
high concentrations. In tobacco formulations comprising high
concentrations of thermoplastic polymers, some users may experience
a "gummy residue" in their mouth upon use of the tobacco
product.
EXAMPLES
[0051] The present invention can be more fully illustrated by the
following examples, which are set forth to illustrate some
embodiments of the present invention and are not to be construed as
limiting thereof. All weight percentages are expressed on a dry
weight basis, meaning water content is excluded, unless otherwise
indicated.
Example 1
Control Formulation
[0052] A tobacco formulation for use as a stick type of a smokeless
tobacco product is provided in the manner set forth in Table 1. The
smokeless tobacco product comprising the tobacco formulation of
Table 1 can be used as a control formulation as compared to the
additional examples of the present invention that are set forth and
described hereinafter.
[0053] The tobacco powder used in Example 1 is a blend of finely
divided (-100/+270 Tyler mesh) flue-cured tobacco lamina and air
cured tobacco stems. All dry ingredients, in powder form, as well
glycerin and propylene glycol, are added together and thoroughly
mixed in a model 300D Littleford horizontal plough dough mixer
(Littleford Day, Inc. Florence, Ky.) for about 15 to 20 minutes at
about 150 rpm. The mixed dry formulation is then commuted into the
hopper of a model ZSK26 Coperion extruder (Werner and Pfeidderer,
Ramsey, N.J.). The extruder barrel has a 30:1 LD (length to
diameter) ratio, 26 inch internal diameter, and consists of 8
heating zones or sections, plus a heated die component.
[0054] The extruder is set at a screw speed of about 45 rpm and the
barrel sections and die operated at temperatures of about
100.degree. C. The extruder is fed at a rate of about 10.5 lb/hr of
dry formulation from a hopper. The formulation is extruded through
a 3.0 mm diameter aperture die into 3 mm diameter cylindrical rods.
Residence time of the formulation in the extruder is approximately
55 seconds. The rods are cut into approximately 61 centimeter long
sticks, and allowed to harden by ambient air drying for about 10 to
20 minutes, after which the sticks are further cut into 3.5 mm long
pieces.
TABLE-US-00001 TABLE 1 Ingredients wt % g Tobacco Powder 36 360
Mannitol 13 180 Sodium chloride 3.6 36 Sodium hydroxide 0.4 4
Sucralose 1 10 Titanium dioxide 1 10 Calcium Carbonate 3 30
Maltodextrin 3 30 Ac-Di-Sol .RTM. 3 30 Glycerin 0.8 8 Cocoa Powder
2 20 Licorice Powder 0.5 5 Vanilla 0.2 2 Hydroxypropyl 28.5 285
Cellulose Propylene Glycol 4 40 Total ingredients: 100% 1000.0
Binder System Formulations
[0055] Tables A-J provide various embodiments of a binder system
that can be incorporated into a tobacco formulation for use in a
tobacco product representative of the present invention. The binder
system prepared according to the recipes shown in Tables A-J can be
used within the tobacco formulations found in the examples
described hereinafter.
[0056] Each batch of binder system is prepared by mixing the
components in a commercially available Kitchen Aid mixer for about
3 to 5 minutes.
TABLE-US-00002 TABLE A Batch 1 Ingredients wt % g Methocel .TM. E
50 70 350 Propylene Glycol 30 150 Total ingredients: 100% 500
TABLE-US-00003 TABLE B Batch 2 Ingredients wt % g Methocel .TM. E
50 42 210 Propylene Glycol 28 140 Water 30 150 Total ingredients:
100% 500
TABLE-US-00004 TABLE C Batch 3 Ingredients wt % g Xanthan 42 210
Maltodextrin 28 140 Propylene Glycol 30 150 Total ingredients: 100%
500
TABLE-US-00005 TABLE D Batch 4 Ingredients wt % g Xanthan 29.4 147
Maltodextrin 19.6 98 Propylene Glycol 21 105 Water 30 150 Total
ingredients: 100% 500
TABLE-US-00006 TABLE E Batch 5 Ingredients wt % g Gum Arabic 42 210
Propylene Glycol 28 140 Water 30 150 Total ingredients: 100%
500
TABLE-US-00007 TABLE F Batch 6 Ingredients wt % g Xanthan 21.7
108.5 Gum Arabic 33.6 168 Plasdone K29/32 14.7 73.5 Propylene
Glycol 30 150 Total ingredients: 100% 500
TABLE-US-00008 TABLE G Batch 7 Ingredients wt % g Gum Arabic 60 300
Maltodextrin (Maltrin 10 DE) 15 75 Propylene Glycol 25 125 Total
ingredients: 100% 500
TABLE-US-00009 TABLE H Batch 8 Ingredients wt % g Maltodextrin
(Maltrin 10 DE) 73 365 Propylene Glycol 27 135 Total ingredients:
100% 500
TABLE-US-00010 TABLE I Batch 9 Ingredients wt % g Modified Starch
(Elastigel .TM. 75 375 1000J) Propylene Glycol 25 125 Total
ingredients: 100% 500
TABLE-US-00011 TABLE J Batch 10 Ingredients wt % g Modified Starch
(INSTANT 65 325 TEXTAID .RTM.-A) Maltodextrin (Maltrin 10 DE) 10 50
Propylene Glycol 25 125 Total ingredients: 100% 500
Examples 2-8
[0057] Tobacco formulations for use as a stick type of a smokeless
tobacco product as set forth in Tables 2-4 are provided in the
following manner.
[0058] A tobacco powder of the type as set forth in Example 1 is
provided. Except for glycerin, all dry ingredients, in powder form,
are added together with a batch formulation and thoroughly mixed in
the model 300D Littleford horizontal plough dough mixer for about
15 to 20 minutes at about 150 rpm. Each batch formulation is
prepared by mixing propylene glycol and/or water with a binder in a
6 L Kitchen Aid mixer for about 5 minutes, before being mixed with
other dry ingredients in the Littleford mixer. Each mixed
formulation is then commuted into the hopper of the ZSK26 Coperion
extruder. Extrusion set-up and operation parameters are essentially
the same as in Example 1, except that barrel heating zones are
operated at about 65.degree. C. to 100.degree. C., and the screw
speed is set at 60 rpm. A wet blend is separately prepared by
mixing, for about 5 minutes, glycerin with water (10 percent total
ingredients formulation equivalent) in a beaker, using a stirring
bar.
[0059] The mixed wet blend formulation is fed into the first barrel
zone of the extruder. The extruder is fed at a rate of 13.5 lb/hr
of dry formulation and 1.5 lb/hr of wet blend formulation. The
formulations are extruded through a 3.0 mm diameter aperture die
into 3 mm diameter rods. The rods are cut into approximately 61 cm
long sticks, and let to harden by ambient air drying for about
10-20 minutes, after which the rods are further cut into 3.5 mm
long sticks.
TABLE-US-00012 TABLE 2 Example 2 Example 3 Ingredients: wt % g wt %
g Tobacco Powder 36 360 36 360 Mannitol 13 130 13 130 Sodium
chloride 3.6 36 3.6 36 Sodium hydroxide 0.4 4 0.4 4 Sucralose 1 10
1 10 Titanium dioxide 1 10 1 10 Calcium Carbonate 3 30 3 30
Maltodextrin 3 30 3 30 Ac-Di-Sol .RTM. 3 30 3 30 Glycerin 0.8 8 0.8
8 Cocoa Powder 2 20 2 20 Licorice Powder 0.5 5 0.5 5 Vanilla 0.2 2
0.2 2 Hydroxypropyl Cellulose 18.5 185 18.5 185 Batch 1 (Table A)
14 140 -- -- Batch 3 (Table C) -- -- 14 140 Total ingredients: 100%
1000.0 100% 1000.0
TABLE-US-00013 TABLE 3 Example 4 Example 5 Ingredients: wt % g wt %
g Tobacco Powder 36 360 36 360 Xylitol 5 50 5 50 Maltitol 5 50 5 50
Sorbitol 5 50 5 50 Sodium chloride 3.6 36 3.6 36 Sodium hydroxide
0.4 4 0.4 4 Sucralose 1 10 1 10 Titanium dioxide 1 10 1 10 Calcium
Carbonate 3 30 3 30 Maltodextrin 3 30 3 30 Ac-Di-Sol .RTM. 3 30 3
30 Glycerin 0.8 8 0.8 8 Cocoa Powder 2 20 2 20 Licorice Powder 0.5
5 0.5 5 Vanilla 0.2 2 0.2 2 Hydroxypropyl Cellulose 18.5 185 18.5
185 Batch 1 (Table A) 12 120 -- -- Batch 2 (Table B) -- -- 12 120
Total ingredients: 100% 1000.0 100% 1000.0
TABLE-US-00014 TABLE 4 Example 6 Example 7 Example 8 Ingredients:
wt % g wt % g wt % g Tobacco Powder 36 360 36 360 36 360 Erythritol
7 70 7 70 7 70 Mannitol 7 70 7 70 7 70 Sodium chloride 3.6 36 3.6
36 3.6 36 Sodium hydroxide 0.4 4 0.4 4 0.4 4 Sucralose 1 10 1 10 1
10 Titanium dioxide 1 10 1 10 1 10 Calcium carbonate 3 30 3 30 3 30
Ac-Di-Sol .RTM. 3 30 3 30 3 30 Glycerin 0.8 8 0.8 8 0.8 8 Cocoa
Powder 2 20 2 20 2 20 Licorice Powder 0.5 5 0.5 5 0.5 5 Vanilla 0.2
2 0.2 2 0.2 2 Hydroxypropyl 18.5 185 18.5 185 18.5 185 Cellulose
Batch 3 (Table C) 16 160 -- -- -- -- Batch 4 (Table D) -- -- 16 160
-- -- Batch 5 (Table E) -- -- -- -- 16 160 Total ingredients: 100%
1000.0 100% 1000.0 100% 1000.0
[0060] A tobacco product prepared as set forth in Examples 2-8 are
prepared in under extrusion conditions at operating temperatures
less than that of Example 1, thereby reducing and/or avoiding the
possibility of charring or scalding the tobacco material, as well
as requiring less energy to maintain higher temperatures.
Additionally, the tobacco products prepared as set forth in
Examples 2-8 have shorter residence times in the extruder, as well
as a higher throughput of product as compared to Example 1.
Examples 9-18
[0061] Tobacco formulations for use as a sheet type of a smokeless
tobacco product as set forth in Tables 5-8 are provided in the
following manner.
[0062] A tobacco powder essentially as set forth in Example 1 is
provided. Each of Examples 9-18 include a flavor emulsion component
having a recipe as set forth in Table K. For Examples 9-12, all
ingredients, including the flavor emulsion are added together and
thoroughly mixed in the model 300D series Littleford plough dough
mixer for about 15 to 20 minutes, at about 150 rpm, before being
commuted into the Coperion extruder hopper. For Examples 13-18, all
ingredients including the flavor emulsion (see Table K) and the
batch formulations are similarly mixed in the Littleford mixer as
described for Example 9-12. For Examples 11-14, a wet blend
solution of percent (v/v) glycerin is prepared.
[0063] For Examples 9-10, the extruder is set at a screw speed of
45 rpm and the barrel sections and die operated at temperatures of
about 100.degree. C. A sheeting die of 75 mm.times.0.85 mm aperture
is employed. The extruder is fed at a rate of 7.5 lb/hr of dry
formulation. No wet blend formulation is used for the Examples
9-10. The dry formulation is extruded into a continuous sheet that
is about 0.85 mm thick. The sheet is extruded onto a conveyor belt
and transferred through a 30 ft long cooling tunnel (ABCO
Automation, Inc, Greensboro, N.C.). The sheet is further reduced in
thickness by passage through three sets of pin rolls, and is
flattened into a sheet having a thickness of less than 0.4 mm. The
sheets are finally cut into bite-size strip pieces of various
shapes (e.g., pieces of about 2 cm by 2 cm).
[0064] For Examples 11-12, pre and post extrusion set-up is similar
to that set forth for Example 9-10, except that extruder screw
speed is set at 50 rpm and a wet blend formulation is employed.
Feed rate is 10.5 lb/hr for the dry blend formulation, and 1.5
lb/hr for the wet blend formulation.
[0065] For Examples 13-14, pre and post extrusion set up is similar
to that set forth in Example 9-10, except that extruder barrel
temperatures are operated at 75.degree. C. to 100.degree. C., screw
speed is set at 60 rpm, and a wet blend formulation is employed.
Feed rate is 13.5 lb/hr for dry blend formulation, and 1.5 lb/hr
wet blend formulation.
TABLE-US-00015 TABLE 5 Example 9 Example 10 Ingredients: wt % g wt
% g Tobacco Powder 37 370 37 370 Mannitol 13.4 134 15 150 Sodium
chloride 3.5 35 3.5 35 Sucralose 0.8 8 0.8 8 Titanium dioxide 1 10
1 10 Polyethylene Glycol 4000 10 100 7.5 75 Maltodextrin 4 40 -- --
Propylene Glycol -- -- 5 50 Flavor Emulsion Ingredients 7.8 78 7.8
78 (see Table K) Ac-Di-Sol .RTM. 2.5 25 2.4 24 Hydroxypropyl
Cellulose 18.6 186 18.6 186 (Klucel .RTM.) Sodium Hydroxide 0.4 4
0.4 4 Sodium Bicarbonate 1 10 1 10 Total ingredients: 100% 1000.0
100% 1000.0
TABLE-US-00016 TABLE 6 Example 11 Example 12 Ingredients: wt % g wt
% g Tobacco Powder 37 370 37 370 Sorbitol 5 50 5 50 Mannitol 9.4 94
10 100 Sodium chloride 3.5 35 3.5 35 Sucralose 0.8 8 0.8 8 Titanium
dioxide 1 10 1 10 Polyethylene Glycol 4000 10 100 7.5 75 Propylene
Glycol -- -- 2 20 Confecto .TM. No-Stick `N` .TM. 3 30 3 30 Flavor
Emulsion Ingredients 7.8 78 7.8 78 (see Table K) Ac-Di-Sol .RTM.
2.5 25 2.4 24 Hydroxypropyl Cellulose 18.6 186 18.6 186 (Klucel
.RTM.) Sodium Hydroxide 0.4 4 0.4 4 Sodium Bicarbonate 1 10 1 10
Total ingredients: 100% 1000.0 100% 1000.0
TABLE-US-00017 TABLE 7 Example 13 Example 14 Example 15 Example 16
Ingredients: wt % g wt % g wt % g wt % g Tobacco Powder 37 370 37
370 37 370 37 370 Mannitol 10.4 104 10.4 104 10.4 104 10.4 104
Sodium chloride 3.5 35 3.5 35 3.5 35 3.5 35 Sucralose 0.8 8 0.8 8
0.8 8 0.8 8 Titanium dioxide 1 10 1 10 1 10 1 10 Polyethylene 7 70
7 70 7 70 7 70 Glycol 4000 Flavor Emulsion 7.8 78 7.8 78 5.8 58 7.8
78 Ingredients (see Table K) Ac-Di-Sol .RTM. 2.5 25 2.5 25 2.5 25
2.5 25 Hydroxypropyl 18.6 186 18.6 186 13.5 135 13.5 135 Cellulose
(Klucel .RTM.) Batch 1 10 100 -- -- -- -- -- -- Batch 6 -- -- 10
100 -- -- -- -- Batch 7 -- -- -- -- 17.1 171 -- -- Batch 8 -- -- --
-- -- -- 15.1 151 Sodium Hydroxide 0.4 4 0.4 4 0.4 4 0.4 4 Sodium 1
10 1 10 1 10 1 10 Bicarbonate Total ingredients: 100% 1000.0 100%
1000.0 100% 1000.0 100% 1000.0
TABLE-US-00018 TABLE 8 Example 17 Example 18 Ingredients: wt % g wt
% g Tobacco Powder 37 370 37 370 Erythritol 15.4 154 -- Sorbitol
liquid (75% solids) -- -- 18 180 Sodium chloride 3.5 35 3.5 35
Sucralose 0.8 8 0.8 8 Titanium dioxide 1 10 1 10 Flavor Emulsion
Ingredients 5.8 58 5.8 58 (see Table K) Ac-Di-Sol .RTM. 2.5 25 2.5
25 Pullulan 13.5 135 13.5 135 Batch 9 17.1 171 -- -- Batch 10 --
14.5 145 Sodium Hydroxide 0.4 4 0.4 4 Sodium Bicarbonate 1 10 1 10
Glycerin 2 20 2 20 Total ingredients: 100% 1000.0 100% 1000.0
TABLE-US-00019 TABLE K Flavor Emulsion Ingredients wt % g Water 70
1050 Gum Arabic 20 300 Flavor key (Menthol Flavor) 10 150 Total
ingredients: 100% 1500
[0066] A tobacco formulation or tobacco product prepared as set
forth in Examples 9-18 can have a lower operating temperature than
that of conventional methods for forming tobacco products, thereby
reducing and/or avoiding the possibility of charring or scalding
the tobacco material as well as requiring less energy to maintain
higher temperatures. Additionally, the tobacco formulations and
tobacco products prepared as set forth in Examples 9-18 can have
relatively short residence times in the extruder as well as
relatively high throughput of processed tobacco product.
[0067] Many modifications and other embodiments of the present
invention will come to mind to one skilled in the art to which this
invention pertains having the benefit of the teachings presented in
the foregoing description. Therefore, it is to be understood that
the invention is not to be limited to the specific embodiments
disclosed and that modifications and other embodiments are intended
to be included within the scope of the appended claims. Although
specific terms are employed herein, they are used in a generic and
descriptive sense only and not for purposes of limitation.
* * * * *