U.S. patent application number 13/441373 was filed with the patent office on 2013-04-25 for vacuum packing methods and apparatus for tobacco.
The applicant listed for this patent is Marcos Andre Steffens. Invention is credited to Marcos Andre Steffens.
Application Number | 20130098785 13/441373 |
Document ID | / |
Family ID | 48135078 |
Filed Date | 2013-04-25 |
United States Patent
Application |
20130098785 |
Kind Code |
A1 |
Steffens; Marcos Andre |
April 25, 2013 |
VACUUM PACKING METHODS AND APPARATUS FOR TOBACCO
Abstract
Apparatus and methods of packing leaf tobacco preserve the
integrity of tobacco, help retain freshness and moisture content of
tobacco, and also help eliminate insect infestation. A packing
container for leaf tobacco includes a carton, and a flexible,
non-porous bag located within the carton. The bag includes a
closeable opening through which the bag receives a quantity of
tightly packed leaf tobacco. The bag is configured to have air
extracted therefrom and to maintain a sub-atmospheric pressure
therein.
Inventors: |
Steffens; Marcos Andre;
(Singapore, SG) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Steffens; Marcos Andre |
Singapore |
|
SG |
|
|
Family ID: |
48135078 |
Appl. No.: |
13/441373 |
Filed: |
April 6, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61549549 |
Oct 20, 2011 |
|
|
|
Current U.S.
Class: |
206/242 ;
53/408 |
Current CPC
Class: |
G01N 31/222 20130101;
G01N 31/229 20130101; B65B 31/04 20130101; B65B 61/20 20130101;
B65B 31/00 20130101; A24F 23/00 20130101; B65D 77/062 20130101;
B65B 29/00 20130101; B65D 81/203 20130101; B65B 1/26 20130101; B65D
85/10 20130101; B65D 81/2038 20130101 |
Class at
Publication: |
206/242 ;
53/408 |
International
Class: |
B65D 85/00 20060101
B65D085/00; B65B 31/04 20060101 B65B031/04 |
Claims
1. A method of packing tobacco, comprising: supplying a quantity of
tightly packed tobacco into a flexible, non-porous bag through a
closeable opening thereof, wherein the bag is positioned within an
open container; closing the opening of the bag; extracting air from
the bag so as to create a sub-atmospheric pressure therein; and
closing the open container such that the bag resides within the
closed container.
2. The method of claim 1, wherein supplying a quantity of tightly
packed tobacco comprises compressing the tobacco within the bag by
forcing a press ram downwardly through the bag opening.
3. The method of claim 1, further comprising inserting a
colorimetric detector within the bag before closing the opening of
the bag, wherein the colorimetric detector is viewable through the
closed bag, and wherein the colorimetric detector is configured to
change color when an environmental condition within the bag changes
and/or when a chemical element associated with the tobacco within
the bag changes.
4. The method of claim 3, wherein the colorimetric detector is
configured to change color when a moisture level and/or temperature
level within the bag is outside of a predetermined range.
5. The method of claim 3, wherein the colorimetric detector is
configured to change color when an oxygen level, nitrogen level
and/or carbon-dioxide level within the bag is outside of a
predetermined range.
6. The method of claim 3, wherein the colorimetric detector is
configured to change color when a chemical element level associated
with the tobacco within the bag is outside of a predetermined
range.
7. The method of claim 6, wherein the chemical element is selected
from the group consisting of nitrosamines, sugars, and oils.
8. The method of claim 1, wherein the bag is formed from a
multi-layered composite material, and wherein at least one of the
layers is an opaque or semi-transparent material.
9. The method of claim 1, wherein the bag is formed from an opaque
or semi-transparent material.
10. The method of claim 1, wherein the bag has a wall thickness of
at least about 100 microns.
11. The method of claim 1, wherein the bag opening is a re-sealable
opening that includes a male zipper portion and a corresponding
female zipper portion configured to matingly engage with the male
zipper portion, and wherein closing the opening of the bag
comprises engaging the male and female zipper portions.
12. The method of claim 11, wherein the re-sealable opening
comprises a slide mechanism movably secured thereto and wherein
closing the bag opening comprises moving the slide mechanism along
the opening to engage the male and female zipper portions.
13. The method of claim 1, wherein the bag comprises a valve, and
wherein extracting air from the sealed bag comprises extracting air
via the valve.
14. The method of claim 1, wherein the bag is configured to
maintain a sub-atmospheric pressure therein of between about 0.10
bar to about 0.80 bar.
15. The method of claim 1, further comprising purging the closed
bag with an inert gas prior to extracting air from the bag.
16. The method of claim 1, wherein the container is a rectangular
carton.
17. The method of claim 1, wherein the tobacco is selected from the
group consisting of Flue Cured Virginia (FCV) tobacco, Burley
tobacco, Oriental tobacco, Sun Cured tobacco, Dark Fired tobacco,
green tobacco, strip tobacco, loose leaf tobacco, bundle tobacco,
butted loose leaf tobacco, and cut rag tobacco.
18-108. (canceled)
109. The method of claim 1, wherein the bag is formed from material
comprising a color that facilitates identification of the type of
tobacco within the bag.
110. The method of claim 1, wherein the bag is formed from material
comprising a color that indicates at least one of destination of
the tobacco, origin of the tobacco, and ownership of the
tobacco.
111. The method of claim 1, wherein the bag is formed from a
multi-layered composite material, and wherein at least one of the
layers comprises a color that facilitates identification of the
type of tobacco within the bag.
112. The method of claim 1, wherein the bag is formed from a
multi-layered composite material, and wherein at least one of the
layers comprises a color that indicates at least one of destination
of the tobacco, origin of the tobacco, and ownership of the
tobacco.
Description
RELATED APPLICATION
[0001] This application claims the benefit of and priority to U.S.
Provisional Patent Application No. 61/549,549 filed Oct. 20, 2011,
the disclosure of which is incorporated herein by reference as if
set forth in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to tobacco and, more
particularly, to tobacco packing.
BACKGROUND
[0003] Leaf or "strip" tobacco, as well as other types of tobacco,
is conventionally packed in rectangular cartons for storage and
shipping. These rectangular cartons are typically constructed of
cardboard and have standardized sizes to reduce transportation and
packing costs. An exemplary cardboard carton 10, also known as a
"C48" carton, is illustrated in FIG. 1. The "C48" designation is
derived from the fact that 48 of these cartons can be placed within
a standard 20 foot shipping container.
[0004] Conventionally, vertically operating tobacco packing presses
are used to fill containers, such as C48 cartons, with tobacco.
Typically, an open C48 carton communicates at its top with an
elongated, hollow, upright charger. The charger supports a column
of tobacco extending upwardly from the carton. A vertically acting
press ram having a press head is aligned above the charger so that
the ram can be operated to force the press head downwardly through
the charger to, or into, the carton. Alternatively, the tobacco
packing press may press the tobacco into a compression chamber,
from where it is further forced into the carton. With the press
head raised, the tobacco is supplied into the top of the charger,
for example by a conveyor positioned below the press head. The
tobacco is supplied until the charger contains a predetermined
quantity of loose uncompacted tobacco (e.g., strip, loose leaf,
bundle, butted loose leaf, cut rag, etc.). The ram is then operated
to force the press head downwardly through the charger and compress
the entire quantity of tobacco into the carton. Exemplary packing
presses are described in U.S. Pat. Nos. 3,641,734 and
4,457,125.
[0005] Unfortunately, conventional packing cartons may not
adequately protect the tobacco therewithin from environmental and
other exposures or from infestation by harmful pests that can
damage or destroy the tobacco.
SUMMARY
[0006] It should be appreciated that this Summary is provided to
introduce a selection of concepts in a simplified form, the
concepts being further described below in the Detailed Description.
This Summary is not intended to identify key features or essential
features of this disclosure, nor is it intended to limit the scope
of the invention.
[0007] Apparatus and methods of packing leaf tobacco, according to
embodiments of the present invention, preserve the integrity of
tobacco, help retain freshness and moisture content of tobacco, and
also help eliminate insect infestation. Embodiments of the present
invention may be used with all types of tobacco including, but not
limited to, Flue Cured Virginia (FCV) tobacco, Burley tobacco,
Oriental tobacco, Sun Cured tobacco, Dark Fired tobacco, etc.
Moreover, green tobacco may be packed in accordance with
embodiments of the present invention. In addition, embodiments of
the present invention may be used with tobacco in all forms
including, but not limited to, strip, loose leaf, bundle, butted
loose leaf, cut rag, etc.
[0008] According to some embodiments of the present invention, a
packing container for tobacco includes a carton, and a flexible,
non-porous bag located within the carton. In some embodiments, the
carton is a rectangular cardboard container, such as a standard C48
or A48 carton. The bag includes a closeable opening through which
the bag receives a quantity of tightly packed tobacco. The bag is
configured to have air extracted therefrom and to maintain a
sub-atmospheric pressure therein of, for example, between about
0.10 bar to about 0.80 bar.
[0009] In some embodiments of the present invention, a colorimetric
detector is inserted within the bag before closing the opening of
the bag. The colorimetric detector is positioned so as to be
viewable through the closed bag or through a portion of the closed
bag. The colorimetric detector is configured to change color when
an environmental condition within the bag changes and/or when a
chemical element associated with the tobacco within the bag
changes. For example, the colorimetric detector may be configured
to change color when a moisture level and/or temperature level
within the bag is outside of a predetermined range. As another
example, the colorimetric detector may be configured to change
color when an oxygen level, nitrogen level, and/or carbon-dioxide
level, for example, within the bag is outside of a predetermined
range. Furthermore, the colorimetric detector may be configured to
change color when a chemical element (e.g., nitrosamines, sugars,
oils, etc.) level associated with the tobacco within the bag is
outside of a predetermined range.
[0010] In some embodiments, the flexible, non-porous bag is formed
from a multi-layered composite material with at least one of the
layers being an aluminum layer. For example, in some embodiments,
the multi-layered composite includes an aluminum layer sandwiched
between first and second polymeric layers. In other embodiments,
the bag is formed from a multi-layered composite having a
polystyrene inner layer, an aluminum middle layer, and a nylon
outer layer. In other embodiments, the bag is formed from a
semi-transparent or opaque material, or is formed from a
multi-layered composite having at least one layer being a
semi-transparent or opaque material.
[0011] A flexible, non-porous bag according to some embodiments of
the present invention may have a wall thickness of at least about
100 microns. In other embodiments, wall thickness may be between
about 100 microns and about 200 microns.
[0012] According to some embodiments of the present invention, the
bag opening is a re-sealable opening including a male zipper
portion and a corresponding female zipper portion that is
configured to matingly engage with the male zipper portion. A slide
mechanism is movably secured to the bag opening and is configured
to slide along the opening and facilitate engagement of the male
and female zipper portions to close the bag.
[0013] According to some embodiments of the present invention, the
bag includes a valve that is utilized for extracting air therefrom.
The valve may also be utilized to purge the bag, when closed, for
example with an inert gas prior to extracting air from the bag.
[0014] According to other embodiments of the present invention, a
packing container for tobacco, comprises a flexible, non-porous bag
having a closeable opening through which the bag receives a
quantity of tightly packed tobacco. The bag is configured to have
air extracted therefrom and to maintain a sub-atmospheric pressure
therein, for example, of between about 0.10 bar to about 0.80 bar.
In some embodiments, the bag is formed from an opaque or
semi-transparent material. In some embodiments the bag is formed
from a multi-layered composite material, and wherein at least one
of the layers comprises aluminum. In some embodiments, the bag is
formed from a multi-layered composite material, and wherein at
least one of the layers is an opaque or semi-transparent material,
or wherein at least one layer has a color that renders the layer
opaque or semi-transparent.
[0015] In some embodiments, the bag has a tubular shape. In other
embodiments, the bag has a generally rectangular or cubic
shape.
[0016] In some embodiments of the present invention, a colorimetric
detector is inserted within the bag before closing the opening of
the bag. The colorimetric detector is positioned so as to be
viewable through the closed bag or a portion of the bag. The
colorimetric detector is configured to change color when an
environmental condition within the bag changes and/or when a
chemical element associated with the tobacco within the bag
changes. For example, the colorimetric detector may be configured
to change color when a moisture level, oxygen level, nitrogen level
and/or carbon-dioxide level within the bag is outside of a
predetermined range, as described above. Moreover, the colorimetric
detector may be configured to change color when a chemical element
(e.g., nitrosamines, sugars, oils, etc.) level associated with the
tobacco within the bag is outside of a predetermined range.
[0017] According to some embodiments of the present invention, a
method of packing tobacco includes supplying a quantity of tightly
packed tobacco into a flexible, non-porous bag through a closeable
opening thereof, wherein the bag is positioned within an open
container; closing the opening of the bag; extracting air from the
bag so as to create a sub-atmospheric pressure therein; and closing
the open container such that the bag resides within the closed
container. The step of supplying a quantity of tightly packed
tobacco into the bag may include compressing the tobacco within the
bag by forcing a press ram downwardly through the bag opening. In
some embodiments, the closed bag is purged with an inert gas prior
to extracting air from the bag.
[0018] According to some embodiments of the present invention, a
method of packing tobacco includes supplying a quantity of tightly
packed tobacco into a flexible, non-porous bag through a closeable
opening thereof; closing the opening of the bag; and extracting air
from the bag so as to create a sub-atmospheric pressure therein.
The step of supplying a quantity of tightly packed tobacco into the
bag may include compressing the tobacco within the bag by forcing a
press ram downwardly through the bag opening. In some embodiments,
the closed bag is purged with an inert gas prior to extracting air
from the bag.
[0019] According to some embodiments of the present invention, a
method of packing tobacco includes supplying a quantity of tightly
packed tobacco into a plurality of flexible, non-porous bags
through a respective closeable opening of each, wherein each bag is
positioned within a respective open rectangular carton; closing the
openings of the bags; extracting air from the bags so as to
maintain a sub-atmospheric pressure therein; closing the open
cartons such that each bag resides within a respective closed
carton; and stacking the closed cartons. In some embodiments, the
closed containers are stacked within a shipping container.
[0020] According to some embodiments of the present invention, a
method of packing tobacco includes supplying a quantity of tightly
packed tobacco into a plurality of flexible, non-porous bags
through a respective closeable opening of each; closing the
openings of the bags; extracting air from the bags so as to
maintain a sub-atmospheric pressure therein; and stacking the
closed bags. In some embodiments, the closed bags are stacked
within a shipping container.
[0021] According to some embodiments of the present invention, a
packing container for leaf tobacco, comprises a carton having a
sealable opening through which the carton receives a quantity of
tightly packed tobacco. The carton is configured to have air
extracted therefrom and to maintain a sub-atmospheric pressure
therein of, for example, between about 0.10 bar to about 0.80 bar.
The carton includes a valve through which air is extracted from the
carton. In some embodiments, the valve is a two-way valve to permit
the carton to be purged with an inert gas prior to extracting air
from the carton.
[0022] In some embodiments of the present invention, the carton
includes a colorimetric detector that is viewable through a window
in the carton. The colorimetric detector is configured to change
color when an environmental condition within the carton changes
and/or when a chemical element associated with the tobacco within
the carton changes. For example, the colorimetric detector may be
configured to change color when a moisture level within the carton
is outside of a predetermined range. The colorimetric detector may
be configured to change color when an oxygen level, nitrogen level
and/or carbon-dioxide level within the carton is outside of a
predetermined range. Furthermore, the colorimetric detector may be
configured to change color when a chemical element (e.g.,
nitrosamines, sugars, oils, etc.) level associated with the tobacco
within the carton is outside of a predetermined range.
[0023] According to some embodiments of the present invention, a
method of packing tobacco includes supplying a quantity of tobacco
into a plurality of open containers; closing the opening
containers; inserting the closed containers within a flexible,
non-porous bag having a closeable opening; closing the opening of
the bag; and extracting air from the bag so as to create a
sub-atmospheric pressure therein. The bag is configured to hold one
or more tobacco containers, such as C48 or A48 cartons. In some
embodiments the bag may be configured to hold up to six containers,
such as C48 or A48 cartons.
[0024] The bag is configured to have air extracted therefrom and to
maintain a sub-atmospheric pressure therein of, for example,
between about 0.10 bar to about 0.80 bar. The flexible, non-porous
bag may be formed from a multi-layered composite material with at
least one of the layers being an aluminum layer. For example, in
some embodiments, the multi-layered composite includes an aluminum
layer sandwiched between first and second polymeric layers. In
other embodiments, the bag is formed from a multi-layered composite
having a polystyrene inner layer, an aluminum middle layer, and a
nylon outer layer. In other embodiments, the bag is formed from a
semi-transparent or opaque material, or is formed from a
multi-layered composite having at least one layer being a
semi-transparent or opaque material.
[0025] The flexible, non-porous bag may have a wall thickness of at
least about 100 microns, and may have a wall thickness between
about 100 microns and about 200 microns. In some embodiments, the
bag opening is a re-sealable opening including a male zipper
portion and a corresponding female zipper portion that is
configured to matingly engage with the male zipper portion.
[0026] According to some embodiments of the present invention, the
bag includes a valve that is utilized for extracting air therefrom.
The valve may also be utilized to purge the bag, when closed, for
example with an inert gas prior to extracting air from the bag.
[0027] It is noted that aspects of the invention described with
respect to one embodiment may be incorporated in a different
embodiment although not specifically described relative thereto.
That is, all embodiments and/or features of any embodiment can be
combined in any way and/or combination. Applicant reserves the
right to change any originally filed claim or file any new claim
accordingly, including the right to be able to amend any originally
filed claim to depend from and/or incorporate any feature of any
other claim although not originally claimed in that manner. These
and other objects and/or aspects of the present invention are
explained in detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The accompanying drawings, which form a part of the
specification, illustrate various embodiments of the present
invention. The drawings and description together serve to fully
explain embodiments of the present invention.
[0029] FIG. 1 is a perspective view of a conventional carton for
storing and shipping tobacco.
[0030] FIG. 2 is a cross sectional view of a flexible, non-porous
bag for receiving tobacco therein, according to some embodiments of
the present invention.
[0031] FIG. 3A is an enlarged, exploded view of a multi-layered
composite material out of which a flexible, non-porous bag for
receiving tobacco therein is formed, according to some embodiments
of the present invention.
[0032] FIG. 3B is an enlarged, exploded view of a multi-layered
composite material out of which a flexible, non-porous bag for
receiving tobacco therein is formed, according to some embodiments
of the present invention.
[0033] FIG. 4 illustrates packing containers, according to some
embodiments of the present invention, on a conveyor for receiving a
quantity of tightly packed tobacco from a packing press.
[0034] FIG. 5 is a perspective view of a flexible, non-porous bag
of one of the packing containers of FIG. 4 after receiving a
quantity of tightly packed tobacco therewithin, after the bag
opening has been closed, and with the filled bag removed from the
carton. The carton is not shown to illustrate that the tobacco is
tightly packed.
[0035] FIG. 6 is a partial perspective view of the closeable
opening of the bag in the packing containers of FIG. 4 and a
sliding mechanism that slides along the opening to facilitate
engagement of the female and male zipper portions, according to
some embodiments of the present invention.
[0036] FIG. 7A is an enlarged perspective view of a valve for
extracting air from the flexible, non-porous bag of FIG. 5,
according to some embodiments of the present invention.
[0037] FIG. 7B is an enlarged perspective view of the valve of FIG.
7A with the cap thereof being moved to an open position.
[0038] FIG. 7C is an enlarged perspective view of the valve of FIG.
7A with the cap thereof in the open position.
[0039] FIG. 7D is an enlarged perspective view of a vacuum tube
about to engage the valve of FIG. 7C for extracting air from the
bag, according to some embodiments of the present invention.
[0040] FIG. 7E illustrates the vacuum tube of FIG. 7D in a seated
position over the mouth of the open valve of FIG. 7C.
[0041] FIG. 8 is a perspective view of a packing container that
includes a carton and a flexible bag therein, according to
embodiments of the present invention, with a quantity of tobacco
within the bag, and after the bag opening has been closed.
[0042] FIG. 9A is a perspective view of a packing container that
includes a carton and a flexible bag therein, according to other
embodiments of the present invention, after the bag has received a
quantity of tobacco therewithin, and after the bag opening has been
closed.
[0043] FIG. 9B illustrates the packing container of FIG. 9A after
air has been extracted from the bag such that the bag has a
sub-atmospheric pressure therein, according to some embodiments of
the present invention.
[0044] FIG. 10 illustrates a plurality of packing containers in a
stacked configuration, according to some embodiments of the present
invention.
[0045] FIG. 11 is a perspective view of a flexible, non-porous bag
for receiving tobacco therein, according to some embodiments of the
present invention.
[0046] FIG. 12 is a perspective view of the flexible, non-porous
bag of FIG. 12 with a quantity of tobacco therewithin and with the
bag opening closed.
[0047] FIG. 13 illustrates a plurality of the flexible, non-porous
bags of FIG. 11 containing tobacco and in a stacked configuration,
according to some embodiments of the present invention.
[0048] FIG. 14 is a perspective view of an insertion frame that
facilitates placement of a flexible, non-porous bag within a
carton, according to some embodiments of the present invention.
[0049] FIG. 15 is a perspective view of a carton receiving a
flexible, non-porous bag with the assistance of the insertion frame
of FIG. 14.
[0050] FIG. 16 is a top perspective view of the carton of FIG. 15
with the flexible, non-porous bag received therein and with the
insertion frame removed.
[0051] FIG. 17 is a top perspective view of a sealable carton
receiving tobacco therein, according to other embodiments of the
present invention.
[0052] FIG. 18 illustrates the carton of FIG. 17 after receiving
tobacco therein, and with the top portions of the carton being
closed.
[0053] FIG. 19 is a top perspective view of a packing container
having a sealed bag containing tobacco within a carton and
illustrating a colorimetric detector within the sealed bag,
according to some embodiments of the present invention.
[0054] FIG. 20 is a perspective view of a sealable packing carton,
according to some embodiments of the present invention, and
including a window through which a colorimetric detector is
visible.
[0055] FIGS. 21-25 illustrate operations for packing tobacco within
tubular-shaped bags, according to other embodiments of the present
invention.
[0056] FIG. 26 illustrates a plurality of tubular-shaped bags
containing tobacco and in a stacked configuration, according to
some embodiments of the present invention.
[0057] FIG. 27A illustrates a flexible, non-porous bag enclosing
multiple cartons of tobacco, according to some embodiments of the
present invention, and prior to extracting air therefrom.
[0058] FIG. 27B illustrates the flexible, non-porous bag of FIG.
27A after air has been extracted therefrom.
DETAILED DESCRIPTION
[0059] The present invention will now be described more fully
hereinafter with reference to the accompanying figures, in which
embodiments of the invention are shown. This invention may,
however, be embodied in many different forms and should not be
construed as limited to the embodiments set forth herein. Like
numbers refer to like elements throughout. In the figures, certain
components or features may be exaggerated for clarity. In addition,
the sequence of operations (or steps) is not limited to the order
presented in the claims unless specifically indicated
otherwise.
[0060] It will be understood that when a feature or element is
referred to as being "on" another feature or element, it can be
directly on the other feature or element or intervening features
and/or elements may also be present. In contrast, when a feature or
element is referred to as being "directly on" another feature or
element, there are no intervening features or elements present. It
will also be understood that, when a feature or element is referred
to as being "connected", "attached" or "coupled" to another feature
or element, it can be directly connected, attached or coupled to
the other feature or element or intervening features or elements
may be present. In contrast, when a feature or element is referred
to as being "directly connected", "directly attached" or "directly
coupled" to another feature or element, there are no intervening
features or elements present. Although described or shown with
respect to one embodiment and/or figure, the features and elements
so described or shown can apply to other embodiments and/or
figures.
[0061] The terminology used herein is for the purpose of describing
particular embodiments only and is not intended to be limiting of
the invention. As used herein, the singular forms "a", "an" and
"the" are intended to include the plural forms as well, unless the
context clearly indicates otherwise. It will be further understood
that the terms "comprises" and/or "comprising," when used in this
specification, specify the presence of stated features, steps,
operations, elements, and/or components, but do not preclude the
presence or addition of one or more other features, steps,
operations, elements, components, and/or groups thereof. As used
herein, the term "and/or" includes any and all combinations of one
or more of the associated listed items and may be abbreviated as
"/". As used herein, phrases such as "between X and Y" and "between
about X and Y" should be interpreted to include X and Y. As used
herein, phrases such as "between about X and Y" mean "between about
X and about Y." As used herein, phrases such as "from about X to Y"
mean "from about X to about Y."
[0062] Spatially relative terms, such as "under", "below", "lower",
"over", "upper" and the like, may be used herein for ease of
description to describe one element or feature's relationship to
another element(s) or feature(s) as illustrated in the Figures. It
will be understood that the spatially relative terms are intended
to encompass different orientations of the device in use or
operation in addition to the orientation depicted in the Figures.
For example, if a device in the Figures is inverted, elements
described as "under" or "beneath" other elements or features would
then be oriented "over" the other elements or features. Thus, the
exemplary term "under" can encompass both an orientation of over
and under. The device may be otherwise oriented (rotated 90 degrees
or at other orientations) and the spatially relative descriptors
used herein interpreted accordingly. Similarly, the terms
"upwardly", "downwardly", "vertical", "horizontal" and the like are
used herein for the purpose of explanation only unless specifically
indicated otherwise.
[0063] It will be understood that although the terms first and
second are used herein to describe various features or elements,
these features or elements should not be limited by these terms.
These terms are only used to distinguish one feature or element
from another feature or element. Thus, a first feature or element
discussed below could be termed a second feature or element, and
similarly, a second feature or element discussed below could be
termed a first feature or element without departing from the
teachings of the present invention.
[0064] Unless otherwise defined, all terms (including technical and
scientific terms) used herein have the same meaning as commonly
understood by one of ordinary skill in the art to which this
invention belongs. It will be further understood that terms, such
as those defined in commonly used dictionaries, should be
interpreted as having a meaning that is consistent with their
meaning in the context of the specification and relevant art and
should not be interpreted in an idealized or overly formal sense
unless expressly so defined herein. Well-known functions or
constructions may not be described in detail for brevity and/or
clarity.
[0065] The term "tobacco", as used herein, includes any and all
types of tobacco including, but not limited to, Flue Cured Virginia
(FCV) tobacco, Burley tobacco, Oriental tobacco, Sun Cured tobacco,
Dark Fired tobacco, green tobacco, and also includes tobacco in
various forms including, but not limited to, strip, loose leaf,
bundle, butted loose leaf, and cut rag.
[0066] Referring now to FIGS. 4-10, a packing container 20 and
methods of packing tobacco in the packing container 20, according
to some embodiments of the present invention, will be described.
The illustrated packing container 20 includes a carton 10, such as
a C48 style carton, A48 style carton (both of which are available
from Jayaraj Fortune Packaging Private Limited, Andhra Pradesh,
India), or other standardized size carton used in the tobacco
industry, and a flexible, non-porous bag 30 located within the
carton 10. Embodiments of the present invention are not limited to
C48 or A48 cartons, or even to rectangular cartons. Various types
and shapes of cartons and containers may be utilized to contain a
flexible, non-porous bag 30 according to embodiments of the present
invention. Moreover, C48 and A48 cartons are typically cardboard
cartons. However, a packing container carton 10, according to
embodiments of the present invention, can be formed from various
materials, without limitation.
[0067] The illustrated non-porous bag 30 includes a closeable
opening 32 through which the bag 30 receives a quantity of tobacco,
for example, tightly packed tobacco from a packing press (70, FIG.
4). The closeable opening 32 is large enough to allow tobacco
packing press equipment to be inserted within a bag 30 to supply a
quantity of tobacco. In the illustrated embodiment, the bag opening
32 is a re-sealable opening that includes a male zipper portion 34
and a corresponding female zipper portion 36 that is configured to
matingly engage with the male zipper portion 34 (FIG. 6). The male
zipper portion 34 includes a plurality of elongated ribs 34a that
are configured to releasably engage respective elongated channels
36a in the female zipper portion 36. A slide mechanism 38 (FIG. 6)
is movably secured to the bag opening 32 and is configured to slide
along the bag opening 32 to facilitate engagement of the male and
female zipper portions 34, 36 in order to close the bag opening 32
after the bag 30 has been supplied with a quantity of tobacco. In
operation, a user moves the slide mechanism 38 back and forth along
the opening 32 one or more time to ensure that the elongated ribs
34a are completely engaged within the elongated channels 36a such
that the bag 30 is sealed closed. The bag opening 32 is configured
to withstand numerous openings and closings without losing
integrity.
[0068] Embodiments of the present invention are not limited to the
configuration of the illustrated bag opening 32 or to the
illustrated configuration of the male and female zipper portions
34, 36. Moreover, embodiments of the present invention are not
limited to zipper-type openings. Various types of re-sealable
openings may be utilized in accordance with embodiments of the
present invention, without limitation. In addition, non-resealable
openings may be utilized. For example, in some embodiments of the
present invention, a bag opening 32 may be heat sealed.
[0069] The illustrated bag 30 also includes a valve 40 (FIG. 4)
that is utilized for extracting air from the bag 30 after receiving
tobacco therein and after the bag opening 32 is sealed closed. The
valve 40 may be a two-way valve to allow the bag 30 to be purged
with an inert gas (e.g., nitrogen, etc.) prior to being used to
extract air from the bag 30. Referring to FIGS. 7A-7E, the
illustrated valve 40 includes a cap 42 that is movable between
closed (FIG. 7A) and open positions (FIG. 7C). When the cap 42 is
in the open position, a vacuum tube 50 (FIGS. 7D, 7E) can engage
the mouth 44 of the valve 40 and extract air from within the bag
30, as would be understood by those skilled in the art. Embodiments
of the present invention are not limited to a particular type of
valve 40. Various types and shapes of valves may be utilized in
accordance with embodiments of the present invention. in some
embodiments, valve 40 is a one-way valve that only permits
extraction of air from a bag 30.
[0070] FIG. 2 is a cross-sectional view illustrating various
dimensions of an exemplary flexible, non-porous bag 30 for packing
containers 20, according to some embodiments of the present
invention. The illustrated bag 30 has an internal length, indicated
by "L-O", and an internal width, indicated by "W-O". an exemplary
dimension for "L-O" is about 130 cm and an exemplary dimension for
"W-O" is about 200 cm. The interior volume 30a has a tapered bottom
portion 30b, as illustrated. The tapered bottom portion 30b has a
length, indicated by "g-o". An exemplary dimension for "g-o" is
about 74 cm. However, other dimensions may be utilized for "W-O",
"L-O", and "g-o". Embodiments of the present invention are not
limited to these particular dimensions.
[0071] The valve 40 is located a distance "a" from the top of the
bag, and is located a distance "b" from the side of the bag, as
illustrated. An exemplary dimension "a" is about 20 cm and an
exemplary dimension "b" is about 100 cm. However, other dimensions
may be utilized for "a" and "b". Embodiments of the present
invention are not limited to these particular dimensions.
[0072] Bags 30 (and 130, FIGS. 11-13), according to embodiments of
the present invention, are not limited to the illustrated
configuration and dimensions of FIG. 2. Bags of various external
and internal shapes and configurations may be utilized, without
limitation. For example, as described below with respect to FIGS.
21-26, a bag may have a tubular shape. Moreover, a valve 40 may be
located in various locations on a bag 30, 130, 330 (FIG. 26).
[0073] Flexible, non-porous bags 30 (and 130, FIGS. 11-13, and 330,
FIGS. 21-26), according to embodiments of the present invention,
are formed from material sufficient to maintain a sub-atmospheric
pressure therein of between about 0.10 bar to about 0.80 bar for an
indefinite period time and to also support the weight of the
tobacco therein. Bags 30, 130, 330 according to embodiments of the
present invention may be configured to maintain a sub-atmospheric
pressure therein anywhere within the range of about 0.10 bar to
about 0.80 bar (e.g., 0.10 bar, 0.11 bar, 0.12 bar, 0.13 bar, 0.14
bar, 0.15 bar, 0.16 bar, 0.17 bar, 0.18 bar, 0.19 bar, 0.20 bar,
0.21 bar, 0.22 bar, 0.23 bar, 0.24 bar, 0.25 bar, 0.26 bar, 0.27
bar, 0.28 bar, 0.29 bar, 0.30 bar, 0.31 bar, 0.32 bar, 0.33 bar,
0.34 bar, 0.35 bar, 0.36 bar, 0.37 bar, 0.38 bar, 0.39 bar, 0.40
bar, 0.41 bar, 0.42 bar, 0.43 bar, 0.44 bar, 0.45 bar, 0.46 bar,
0.47 bar, 0.48 bar, 0.49 bar, 0.50 bar, 0.51 bar, 0.52 bar, 0.53
bar, 0.54 bar, 0.55 bar, 0.56 bar, 0.57 bar, 0.58 bar, 0.59 bar,
0.60 bar, 0.61 bar, 0.62 bar, 0.63 bar, 0.64 bar, 0.65 bar, 0.66
bar, 0.67 bar, 0.68 bar, 0.69 bar, 0.70 bar, 0.71 bar, 0.72 bar,
0.73 bar, 0.74 bar, 0.75 bar, 0.76 bar, 0.77 bar, 0.78 bar, 0.79
bar, 0.80 bar, etc. Moreover, bags 30 (and 130, FIGS. 11-13, and
330, FIGS. 21-26) according to embodiments of the present invention
can be configured to maintain a sub-atmospheric pressure therein in
any range within the range of 0.10 bar to 0.80 bar (e.g., 0.10 bar
to 0.20 bar; 0.20 bar to 0.30 bar; 0.30 bar to 0.40 bar; 0.40 bar
to 0.50 bar; 0.50 bar to 0.60 bar; 0.60 bar to 0.70 bar; 0.70 bar
to 0.80 bar; etc.).
[0074] Sub-atmospheric pressure may be varied in order to control
aging and/or fermentation of tobacco stored within bags 30 (and
130, FIGS. 11-13, and 330, FIGS. 21-26), according to embodiments
of the present invention. For example, some customers may desire a
certain aging rate and/or fermentation of tobacco within a bag 30,
130, 330 which can be controlled via the sub-atmospheric pressure
within the bag 30, 130, 330.
[0075] In some situations, a packing container 20 filled with
tobacco in accordance with embodiments of the present invention may
be stored for years. The internal bag 30 is designed to maintain
the desired sub-atmospheric pressure for the entire length of the
storage. The non-porous characteristic of the bag material
prohibits insects and other pests from detecting the presence of
tobacco within the bag 30 because no smell (e.g., tobacco odor) can
escape from the bag 30.
[0076] An exemplary wall thickness of flexible, non-porous material
for use in bags 30, according to embodiments of the present
invention, is about 100 microns. However, material with different
wall thicknesses, higher or lower than 100 microns, may be
utilized. In some embodiments, a wall thickness of flexible,
non-porous material for use in bags 30 may be between about 100
microns and about 200 microns. However, any size within this range
may be utilized e.g., 101 microns, 102 microns, 103 microns, 104
microns, 105 microns, 106 microns, 107 microns, 108 microns, 109
microns, 110 microns, 111 microns, 112 microns, 113 microns, 114
microns, 115 microns, 116 microns, 117 microns, 118 microns, 119
microns, 120 microns, 121 microns, 122 microns, 123 microns, 124
microns, 125 microns, 126 microns, 127 microns, 128 microns, 129
microns, 130 microns, 131 microns, 132 microns, 133 microns, 134
microns, 135 microns, 136 microns, 137 microns, 138 microns, 139
microns, 140 microns, 141 microns, 142 microns, 143 microns, 144
microns, 145 microns, 146 microns, 147 microns, 148 microns, 149
microns, 150 microns, 151 microns, 152 microns, 153 microns, 154
microns, 155 microns, 156 microns, 157 microns, 158 microns, 159
microns, 160 microns, 161 microns, 162 microns, 163 microns, 164
microns, 165 microns, 166 microns, 167 microns, 168 microns, 169
microns, 170 microns, 171 microns, 172 microns, 173 microns, 174
microns, 175 microns, 176 microns, 177 microns, 178 microns, 179
microns, 180 microns, 181 microns, 182 microns, 183 microns, 184
microns, 185 microns, 186 microns, 187 microns, 188 microns, 189
microns, 190 microns, 191 microns, 192 microns, 193 microns, 194
microns, 195 microns, 196 microns, 197 microns, 198 microns, 199
microns, 200 microns, etc.
[0077] In addition, bags 30 according to embodiments of the present
invention may be formed from a single layer of material or from a
multi-layered composite material (e.g., 3 layers, 4 layers, 5
layers, 7 layers or more). FIG. 3A illustrates an exemplary three
layer material 60 wherein the first layer 62a is nylon, the middle
layer 62b is aluminum, and the third layer 62c is polystyrene.
However, various polymeric materials may be utilized for the first
and third layers 62a, 62c. Embodiments of the present invention are
not limited to multi-layered composites utilizing only nylon and
polystyrene. In addition, embodiments of the present invention are
not limited to multi-layered composites utilizing an aluminum
layer. Other layers of metallic, non transparent material may be
utilized in accordance with embodiments of the present
invention.
[0078] Bags 30 according to embodiments of the present invention do
not require a metallic material. According to other embodiments of
the present invention, an internal bag 30 may be formed from an
opaque or semi-transparent material, or may be formed from a
multi-layered composite having at least one layer being an opaque
or semi-transparent material.
[0079] In other embodiments of the present invention, the layers
62a, 62b, 62c of bag 30 in FIG. 3A can be formed from polymeric
material with at least one of the layers being opaque or
semi-transparent. For example, one of the layers can be formed from
opaque or semi-transparent material or can have a color (e.g.,
blue, black, etc.) that renders the layer opaque or
semi-transparent.
[0080] FIG. 3B illustrates an exemplary seven layer material 60 for
an internal bag 30 having layers 62a-62g. Each of the layers (i.e.,
62a, 62b, 62c, 62d, 62e, 62f, 62g) can be a polymeric material. In
some embodiments of the present invention, at least one of the
layers is formed from an opaque or semi-transparent material. In
some embodiments of the present invention, at least one of the
layers has a color that renders the layer opaque or
semi-transparent.
[0081] The thickness of individual layers in a multi-layer
composite (FIGS. 3A and 3B), according to embodiments of the
present invention, may be different depending on the type of
material used. For example, in the illustrated embodiment of FIG.
3A, the nylon layer 62a may have a thickness of about 15 microns,
the aluminum layer 62b may have a thickness of about 25 microns,
and the polystyrene layer 62c may have a thickness of about 60
microns.
[0082] Referring back to FIG. 4, a packing container 20 according
to some embodiments of the present invention is positioned beneath
a tobacco packing press 70 for receiving a quantity of tightly
packed tobacco 80. After the packing container 20 receives the
tobacco 80 within the internal bag 30, the packing container 20 is
moved along a conveyor to a closing station (not shown) and the
next packing container 20 is moved into position beneath the
tobacco packing press 70. At the closing station, the bag opening
32 is closed and air is extracted from within the bag 30, as
described above. In some embodiments of the present invention, the
tobacco 80 may be subjected to a blanket of inert gas prior to
evacuating the air therefrom. The inert gas may help kill any pests
or organisms (e.g., insects, bacteria, fungi, etc.) present in the
tobacco 80 and may help reduce the oxygen concentration in any
remaining air within the bag 30 after a sub-atmospheric pressure
has been induced therewithin.
[0083] FIG. 5 illustrates a closed bag 30 from a packing container
20 according to some embodiments of the present invention and
having a quantity of tightly packed tobacco 80 disposed
therewithin. The carton 10 is not illustrated so that the amount of
packing of the tobacco within the bag 30 can be observed. FIG. 8
illustrates the closed bag 30 of FIG. 5 positioned within an open
carton 10.
[0084] Referring to FIGS. 9A-9B, a packing container 20, according
to some embodiments of the present invention, is illustrated. The
illustrated bag 30 within the carton 10 is formed from a
multi-layer composite having an aluminum layer 64. As illustrated,
the aluminum layer completely surrounds the tobacco contents and
prohibits any light from reaching the tobacco. The aluminum layer
also facilitates detection of the bag 30 within a closed and sealed
carton 10, for example, via metal detection equipment, etc. In
addition, FIG. 9A illustrates the bag 30 prior to having air
extracted from the bag 30. FIG. 9B illustrates the bag 30 of FIG.
9A after air has been extracted from the bag 30 such that the bag
30 has a sub-atmospheric pressure therein.
[0085] In other embodiments of the present invention, an opaque or
semi-transparent material, other than aluminum may be utilized. For
example, a polymeric layer having a color that inhibits light from
passing therethrough may be utilized.
[0086] Referring to FIGS. 14 and 15, an insertion frame 90 may be
utilized to facilitate insertion of flexible, non-porous bags 30
within cartons 10, according to some embodiments of the present
invention. The insertion frame 90 allows a bag that is sized to
conform with the interior of a carton 10 (thereby reducing extra,
unneeded bag material) to be easily and quickly installed within a
carton 10. As illustrated in FIG. 14, a bag 30 is initially
inserted over the insertion frame 90. The frame 90 and bag 30
assembly is then rotated and inserted within a carton 10, as
illustrated in FIG. 15, with the open end of the bag 30 facing
outwardly (e.g., upwardly). The frame 90 is then removed from the
bag (FIG. 16) prior to tobacco being received within the bag
30.
[0087] FIG. 10 illustrates a plurality of packing containers 20,
each of which contains a flexible, non-porous bag 30 with a
quantity of tightly packed tobacco therewithin, according to
embodiments of the present invention. The packing containers 20 are
in a stacked configuration. The stacked configuration may be a
stored configuration. The stacked configuration may also be a
preliminary step to placing the packing containers 20 in a shipping
container.
[0088] According to other embodiments of the present invention,
tobacco may be packed, shipped, and/or stored within standalone
flexible, non-porous bags 130, as illustrated in FIGS. 11-13,
without the use of an external carton 10 or other container. Bags
130 of various shapes and configurations may be utilized. Moreover,
although not required, such bags 130 may be formed from material
having a wall thickness greater than 200 microns in order to
withstand potential damage from handling and shipping. In addition,
standalone bags 130, according to embodiments of the present
invention, are capable of supporting at least between about 15
kilograms and about 240 kilograms of tobacco.
[0089] Standalone bags 130, according to embodiments of the present
invention, may be formed from an opaque or semi-transparent
material, or may be formed from a multi-layered composite material,
wherein at least one of the layers is an opaque or semi-transparent
material, as described above.
[0090] The illustrated standalone non-porous bag 130 includes a
closeable opening 32 through which the bag 130 receives a quantity
of tightly packed tobacco, as described above. The closeable
opening 32 is large enough to allow tobacco packing press equipment
to be inserted within a bag 130 to supply a quantity of tobacco.
The bag opening 32 is a re-sealable opening that includes a male
zipper portion 34 and a corresponding female zipper portion 36 that
is configured to matingly engage with the male zipper portion 34,
as described above. Although not illustrated, a slide mechanism
(e.g., 38, FIG. 6) may be provided that is movably secured to the
bag opening 32 and is configured to slide along the bag opening 32
to facilitate engagement of the male and female zipper portions 34,
36 in order to close the bag opening 32 after the bag 130 has been
supplied with a quantity of tobacco. The illustrated standalone bag
130 also includes a valve 40 that is utilized for extracting air
from the bag 30 after receiving tobacco therein and after the bag
opening 32 is sealed closed, as described above. The valve 40 may
also be utilized to purge the bag 130, when closed, with an inert
gas (e.g., nitrogen, etc.) prior to extracting air from the bag
130.
[0091] In some embodiments of the present invention, a standalone
bag 130 may include a rigid member 140 disposed within the bag 130
that receives the tobacco thereon. Rigid member 140 can facilitate
stacking (FIG. 13) of multiple standalone bags 130 by providing a
generally flat surface at the bottom of each standalone bag 130.
Moreover, rigid member 140 can provide structural support for a bag
130. Rigid member 140 can have various shapes and configurations,
and is not limited to the illustrated configuration.
[0092] Flexible non-porous bags 30, 130, 330 according to
embodiments of the present invention can be re-used and/or
recycled. As such, embodiments of the present invention are
environmentally friendly and may reduce costs associated with
disposal.
[0093] Referring now to FIGS. 17 and 18, a packing container 220,
according to other embodiments of the present invention, is
illustrated. The illustrated packing container 220 is a sealable
carton that does not require the use of an internal bag (e.g., bag
30, FIG. 5). The container 220 includes a closeable opening 222
through which the container 220 receives a quantity of tightly
packed tobacco. In the illustrated embodiment, the container 220
includes opposing upper wall members 224, 226 that are configured
to fold together, as illustrated in FIGS. 18 and 20. The edge
portions 224a, 226a of respective wall members 224, 226 are
configured to be sealed together such that the interior of the
container 220 is airtight and can maintain a vacuum therein. In
some embodiments, the edge portions 224a, 226a can be sealed
together in a fashion similar to that of an aseptic package, such
as a milk carton, and such that, once opened after sealing, cannot
be resealed together. For example, the edge portions 224a, 226a may
be heat sealed together or may be adhesively sealed together. In
other embodiments, the edge portions 24a, 226a can have a
configuration that allows then to be resealable to facilitate
multiple openings and closings thereof.
[0094] The packing container 220 is configured to have air
extracted therefrom and to maintain a sub-atmospheric pressure
therein of, for example, between about 0.10 bar to about 0.70 bar.
The illustrated packing container 220 also includes a valve 40, as
described above, that is utilized for extracting air from the
packing container 220 after receiving tobacco therein and after the
packing container 220 is sealed closed. As described above, the
valve 40 may be a two-way valve to allow the packing container 220
to be purged with an inert gas (e.g., nitrogen, etc.) prior to
extracting air from the packing container 220. However, embodiments
of the present invention are not limited to a particular type of
valve 40. Various types and shapes of valves may be utilized in
accordance with embodiments of the present invention. Moreover,
valve 40 can be a one-way valve in some embodiments and a two-way
valve in other embodiments.
[0095] Referring to FIG. 19, a packing container 20, according to
some embodiments of the present invention, may include a
colorimetric detector 100 within an internal bag 30 that is visible
upon opening the carton 10. For example, for transparent bags, the
colorimetric detector 100 can be viewed through the bag 30, as
illustrated in FIG. 19. In other embodiments wherein an internal
bag 30 is opaque or semi-transparent, a transparent window may be
provided in the bag 30 so as to view a colorimetric detector 100
within the bag 30.
[0096] A colorimetric detector 100, according to embodiments of the
present invention, includes one or more chemical reagents thereon
(e.g., arranged within a display) that, when exposed to in
particular environmental conditions and/or chemical elements,
visually change color. For example, a chemical reagent may be
configured to change color when moisture level (e.g., humidity
level) within a sealed bag 30 falls below (or rises above) a
predetermined level. Another chemical reagent may be configured to
change color when oxygen levels within a sealed bag 30 increase
(e.g., indicative of a leak). Chemical reagents may be utilized to
measure changes (increases or decreases) in other environmental
conditions within a sealed bag 30 including, but not limited to,
nitrogen level, carbon-dioxide level, temperature etc.
[0097] Another chemical reagent may be configured to change color
when a level of a chemical element associated with the tobacco
within a sealed bag 30 changes. For example, changes in nitrosamine
levels (increases or decreases) within the tobacco may be detected
and thereby indicated by a change in reagent color. Changes in the
level (increases or decreases) of other tobacco chemicals, such as
tobacco leaf sugars and oils may also be detected. Chemical
reagents and their use with colorimetric detection are well known
and need not be described further herein.
[0098] A colorimetric detector 100, according to embodiments of the
present invention, may be formed of virtually any material
sufficient to retain one or more reagents. In some embodiments, a
colorimetric detector 100 may be a piece of paper or other
substrate containing one or more reagents. In addition, a
colorimetric detector 100, according to embodiments of the present
invention, can have various shapes and sizes, without limitation.
Embodiments of the present invention are not limited to the
illustrated shape or size of the colorimetric detector 100 of FIG.
19. In addition, various indicia (e.g., one or more numerical
scales, etc.) may be provided with a colorimetric detector 100 to
facilitate quantification of how much change has occurred in a
particular condition and/or element. For example, a humidity level
scale may be provided to indicate moisture levels (e.g., 10%, 20%,
30%, 40%, 50%, etc.). Other similar scales may be provided for
other conditions/elements.
[0099] Various types and configurations of colorimetric detectors
may be utilized with the various embodiments of the present
invention described herein. In addition, colorimetric detectors may
be utilized to monitor changes in more than one environmental
condition and/or changes in more than one chemical element.
[0100] Referring to FIG. 20, a sealable packing container 220, as
described above with respect to FIGS. 17 and 18, includes a
transparent window 230 through which a colorimetric detector 100
within the sealed packing container 220 can be viewed, according to
some embodiments of the present invention. As such, the conditions
within the sealed packing container 220 can be viewed from the
outside without requiring the sealed container 220 to be opened. As
described above, the colorimetric detector 100 can be utilized to
detect changes in moisture level, oxygen level, nitrogen level,
carbon-dioxide level, temperature, as well as changes in various
tobacco leaf chemicals such as nitrosamines, oils and sugars.
[0101] According to other embodiments of the present invention,
tobacco may be packed, shipped, and/or stored within standalone
flexible, non-porous bags 330 having a tubular shape, as
illustrated in FIGS. 21-26. Although not required, such bags 330
may be formed from material having a wall thickness greater than
200 microns in order to withstand potential damage from handling
and shipping. In addition, standalone bags 330, according to
embodiments of the present invention, are capable of supporting at
least between about 15 kilograms and about 240 kilograms of
tobacco.
[0102] Standalone bags 330, according to embodiments of the present
invention, may be formed from an opaque or semi-transparent
material, or may be formed from a multi-layered composite material,
wherein at least one of the layers is an opaque or semi-transparent
material, as described above.
[0103] In one embodiment of the present invention, the standalone
non-porous bags 330 are produced by providing an elongated tube 300
having an open first end 300a and an opposite closed end 300b
(FIGS. 21-23). The elongated tube 300 is provided with a plurality
of valves 40 at predetermined intervals on the elongated tube 300.
For example, a valve 40 may be provided every three feet, four
feet, or some other constant dimension.
[0104] A predetermined amount of tobacco is fed into the elongated
tube 300 and the tube 300 is cut in multiple locations, as
illustrated in FIG. 23, to produce a plurality of separate
tube-shaped bags 330 (FIG. 24). The open ends of the tube-shaped
bags 330 are then sealed (e.g., heat sealed). Air is then extracted
from each bag 330 via a respective valve 40 to create a
sub-atmospheric pressure therein, as described above. The
tube-shaped bags 330 can be packed within cartons or may be stacked
by themselves.
[0105] Tubular shaped bags 330, according to embodiments of the
present invention, may be formed and packed with tobacco in various
ways. Embodiments of the present invention are not limited to the
operations illustrated in FIGS. 21-25.
[0106] A colorimetric detector may be utilized with a standalone
non-porous bags 330, as described above, to monitor one or more
conditions within the sealed bag 330. As described above, a
colorimetric detector 100 can be utilized to detect changes in
moisture level, oxygen level, nitrogen level, carbon-dioxide level,
temperature, as well as changes in various tobacco leaf chemicals
such as nitrosamines, oils and sugars.
[0107] Referring to FIGS. 27A-27B, a flexible, non-porous bag 430
according to other embodiments of the present invention is
illustrated. The bag 430 is configured to enclose multiple
containers 10 (e.g., cartons, such as C48, A48 cartons, etc.). In
the illustrated embodiment, six (6) cartons 10 are enclosed in the
bag 430. However, any number of containers 10 (e.g., 1, 2, 3, 4, 5,
6, or more) may be included within a bag 430. Embodiments of the
present invention are not limited to the illustrated six (6)
containers 10.
[0108] The illustrated bag 430 includes a closeable opening 32 and
is configured to have air extracted therefrom and to maintain a
sub-atmospheric pressure therein of, for example, between about
0.10 bar to about 0.80 bar. FIG. 27A illustrates the flexible,
non-porous bag 430 enclosing multiple cartons 10 of tobacco, with
the opening 32 closed, and prior to extracting air from the bag
430. FIG. 27B illustrates the flexible, non-porous bag 430 of FIG.
27A after air has been extracted therefrom.
[0109] In some embodiments, the bag opening 32 is a re-sealable
opening including a male zipper portion and a corresponding female
zipper portion that is configured to matingly engage with the male
zipper portion, such as described above.
[0110] The flexible, non-porous bag 430 may be formed from a
multi-layered composite material with at least one of the layers
being an aluminum layer. For example, in some embodiments, the
multi-layered composite includes an aluminum layer sandwiched
between first and second polymeric layers. In other embodiments,
the bag 430 is formed from a multi-layered composite having a
polystyrene inner layer, an aluminum middle layer, and a nylon
outer layer. In other embodiments, the bag 430 is formed from a
semi-transparent or opaque material, or is formed from a
multi-layered composite having at least one layer being a
semi-transparent or opaque material.
[0111] The flexible, non-porous bag 430 may have a wall thickness
of at least about 100 microns, and may have a wall thickness
between about 100 microns and about 200 microns. According to some
embodiments of the present invention, the bag includes a valve 40
that is utilized for extracting air therefrom. The valve 40 may
also be utilized to purge the bag, when closed, for example with an
inert gas prior to extracting air from the bag 430.
[0112] A colorimetric detector may be utilized with a non-porous
bags 430, as described above, to monitor one or more conditions
within the sealed bag 430. As described above, a colorimetric
detector 100 can be utilized to detect changes in moisture level,
oxygen level, nitrogen level, carbon-dioxide level, temperature, as
well as changes in various tobacco leaf chemicals such as
nitrosamines, oils and sugars.
[0113] In some embodiments of the present invention, the various
bags 30, 130, 330, 430 (as well as carton 220) described above can
be formed from material having a color that facilitates
identification of the type of tobacco therewithin. Color may also
be utilized to indicate destination of the tobacco, origin of the
tobacco, ownership of the tobacco, etc.
[0114] Packing containers 20 (FIGS. 4-10), 130 (FIGS. 11-13), 220
(FIGS. 17-18), 330 (FIGS. 21-26), 430 (FIGS. 27A-27B) according to
embodiments of the present invention have numerous advantages over
conventional tobacco shipping/storage cartons. For example,
maintaining tobacco under vacuum helps retain the freshness and
flavor of the tobacco up to 3 to 5 times longer than in
conventional shipping/storage containers. Moreover, maintaining
tobacco under vacuum helps prevent loss in moisture content of the
tobacco (e.g., preserve the level of moisture of the tobacco at the
time of packing) and also prevents mold formation. Because moisture
content is maintained, the tobacco leaves retain their color
(maintain their "color line") and shape and are less likely to be
susceptible to breakage. Thus, sealed bags 30, 130, 330, 430
according to embodiments of the present invention can preserve the
particle size distribution (PSD) of the packed tobacco, thereby
maintaining the quality and value of the tobacco.
[0115] By maintaining the "color line" is meant that the color of
the tobacco leaf is retained during shipping and storage. Thus, as
a non-limiting example, a tobacco packed with a color line of
"lemon" will retain its "lemon" color line and be "lemon" colored
when the tobacco reaches its final destination and is opened for
further processing. Similarly, a tobacco packed with a color line
of, for example, "light orange," "orange," or "mahogany" will
retain the respective color line throughout transport and storage
in the sealed internal bags 30 according to embodiments of the
present invention as compared to tobacco that is packed in a
conventional manner.
[0116] Sealed bags 30, 130, 330, 430 (and sealed cartons 220)
according to embodiments of the present invention also protect
tobacco against environmental exposure, including changes of
weather conditions (e.g., changes in temperature, changes in
humidity, etc.), which can harm tobacco quality. Sealed bags 30,
130, 330, 430 (and sealed cartons 220) also protect tobacco against
liquids and odors. In addition, sealed bags 30, 130, 330, 430 (and
sealed cartons 220) protect tobacco against sub-zero temperatures
that may be encountered in some storage and/or transportation
environments.
[0117] Another potential benefit resulting from the use of the
sealed bags 30, 130, 330, 430 and sealed cartons 220 according to
embodiments of the present invention may be the reduction of
tobacco-specific nitrosamines (TSNAs). By protecting the tobacco
from exposure to environmental changes such as high humidity and/or
high temperature as well as exposure to microorganisms (e.g.,
bacteria, fungi, and the like), the level of TSNAs in the tobacco
leaves enclosed in the sealed bags 30, 130, 330, 430 according to
embodiments of the present invention may be reduced as compared
with tobacco leaves that are not so enclosed.
[0118] The sub-atmospheric pressure within a bag 30, 130, 330, 430
(or carton 220) according to embodiments of the present invention
lowers the amount of oxygen within the bag which will kill any
insects or other pests (e.g., tobacco beetles, tobacco moths,
microorganisms, etc.) that may be present in the tobacco. The
non-porous nature of the bag material also prevents insects and
other pests from finding (i.e., smelling) tobacco therewithin.
Thus, the bag material of a bag 30, 130, 330, 430 (and the material
of a carton 220) according to embodiments of the present invention
provides not only a barrier to insect/pest penetration but also
reduces the escape of tobacco odors that attract insects/pests.
Because there is reduced risk of insect infestation, there is less
need for fumigation of tobacco prior to or during packing, which
can result in cost savings.
[0119] Further, it is noted that the use of fumigants in tobacco
packaging has led to pest populations with increased resistance to
those fumigants. Thus, a reduced need for fumigation that may
result from the use of sealed bags 30, 130, 330, 430 and cartons
220 according to embodiments of the present invention may also
provide the benefit of reducing the level of resistance among the
insects and pests that typically infest tobacco.
[0120] A further advantage resulting from the use of the sealed
bags 30, 130, 330, 430 and cartons 220 according to embodiments of
the present invention is the maintenance of the leaf chemistry.
Thus, for example, the lower oxygen concentration reduces oxidation
of tobacco, thereby preserving tobacco flavors and oils. Therefore,
in some embodiments, the level of volatile oil(s) present in the
tobacco at the time of packing is preserved. Accordingly, in one
embodiment, the level of volatile oil(s) in tobacco packed using
the sealed bags 30, 130, 330, 430 and cartons 220 according to
embodiments of the present invention is about 100% to about 50%
retained as compared to the level of retention of volatile oil(s)
in the same tobacco but which has been packed in a conventional
manner. In other embodiments, the level of volatile oil(s) in
tobacco packed in the sealed bags 30, 130, 330, 430 and cartons 220
according to embodiments of the present invention is retained at
about 100%, 99%, 98%, 97%, 96%, 95%, 94%, 93%, 92%, 91%, 90%, 89%,
88%, 87%, 86%, 85%, 84%, 83%, 82%, 81%, 80%,79%, 78%, 77%, 76%,
75%, 74%, 73%, 72%, 71%, 70%, 69%, 68%, 67%, 66%, 65%, 64%, 63%,
62%, 61%, 60%,59%, 58%, 57%, 56%, 55%, 54%, 53%, 52%, 51%, 50%, or
any range therein, or any combination thereof, as compared to the
level of retention of volatile oil(s) in the same tobacco but which
has been packed in a conventional manner.
[0121] In addition, the level of sugars (e.g., reducing sugars)
present in the tobacco at the time of packing can also be
maintained or preserved through the use of the sealed bags 30, 130,
330, 430 and cartons 220 according to embodiments of the present
invention. Non-limiting examples of sugars present in tobacco leaf
include sucrose, fructose, glucose, galactose, arabinose, maltose,
deoxyribose, mannose, pentose, raffinose, planteose, rhamnose,
ribose, xylose, and the like. Thus, in one embodiment, the level of
sugars in tobacco packed in the sealed bags 30, 130, 330, 430 and
cartons 220 according to embodiments of the present invention is
about 100% to about 50% as compared to the level of sugars in the
same tobacco that has been packed in a conventional manner. In
other embodiments, the level of sugars in tobacco packed in the
sealed bags 30, 130, 330, 430 and cartons 220 according to
embodiments of the present invention is about 100%, 99%, 98%, 97%,
96%, 95%, 94%, 93%, 92%, 91%, 90%, 89%, 88%, 87%, 86%, 85%, 84%,
83%, 82%, 81%, 80%,79%, 78%, 77%, 76%, 75%, 74%, 73%, 72%, 71%,
70%, 69%, 68%, 67%, 66%, 65%, 64%, 63%, 62%, 61%, 60%,59%, 58%,
57%, 56%, 55%, 54%, 53%, 52%, 51%, 50%, or any range therein, or
any combination thereof, as compared to the level of sugars in the
same tobacco but which has been packed in a conventional manner.
Thus, in one embodiment, tobacco having total reducing sugars of
about 20%, when packed in sealed bags 30, 130, 330, 430 and cartons
220 according to embodiments of the present invention, would have
total reducing sugars of about 20% when unpacked (i.e., 100%
retention) as compared to the level of sugars in the same tobacco
but which has been packed in a conventional manner. In other
embodiments, tobacco having total reducing sugars of 20%, when
packed in sealed bags 30, 130, 330, 430 and cartons 220 according
to embodiments of the present invention, would have total reducing
sugars of about 20% to about 10% when unpacked (i.e., about 100% to
about 50% retention).
[0122] The sub-atmospheric pressure within bags 30, 130, 330, 430
and cartons 220 according to embodiments of the present invention
also increases, for example, by 20% to 40%, the amount of tobacco
that can be packed within a container. As such, packing containers
20, 220 and bags 30, 130, 330, 430 according to embodiments of the
present invention can save costs associated with storage and
containers. In addition, packing containers, according to
embodiments of the present invention, provide an opportunity to
ship more tobacco by weight per carton (e.g., per C48 carton),
thereby reducing overall freight costs.
[0123] The foregoing is illustrative of the present invention and
is not to be construed as limiting thereof. Although a few
exemplary embodiments of this invention have been described, those
skilled in the art will readily appreciate that many modifications
are possible in the exemplary embodiments without materially
departing from the novel teachings and advantages of this
invention. Accordingly, all such modifications are intended to be
included within the scope of this invention as defined in the
claims. The invention is defined by the following claims, with
equivalents of the claims to be included therein.
* * * * *