U.S. patent application number 14/505834 was filed with the patent office on 2015-04-09 for dissolvable-chewable tobacco tablet.
The applicant listed for this patent is Altria Client Services Inc.. Invention is credited to William J. Burke, Feng Gao, Diane L. Gee, Phillip M. Hulan, Shuzhong Zhuang.
Application Number | 20150096574 14/505834 |
Document ID | / |
Family ID | 52775953 |
Filed Date | 2015-04-09 |
United States Patent
Application |
20150096574 |
Kind Code |
A1 |
Gao; Feng ; et al. |
April 9, 2015 |
DISSOLVABLE-CHEWABLE TOBACCO TABLET
Abstract
A tobacco tablet that includes a solid solution of soluble fiber
and one or more sugar alcohols, the solid solution having a glass
transition temperature of less than 40.degree. C., and tobacco
dispersed in the solid solution such that the tobacco is released
from the tablet when the tablet is chewed or dissolved within an
oral cavity.
Inventors: |
Gao; Feng; (Midlothian,
VA) ; Gee; Diane L.; (Chesterfield, VA) ;
Hulan; Phillip M.; (Midlothian, VA) ; Zhuang;
Shuzhong; (Glen Allen, VA) ; Burke; William J.;
(Nashville, TN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Altria Client Services Inc. |
Richmond |
VA |
US |
|
|
Family ID: |
52775953 |
Appl. No.: |
14/505834 |
Filed: |
October 3, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61886325 |
Oct 3, 2013 |
|
|
|
Current U.S.
Class: |
131/275 ;
131/111; 131/352 |
Current CPC
Class: |
A24B 15/16 20130101;
A24B 13/00 20130101; A24B 15/303 20130101; A24B 15/10 20130101 |
Class at
Publication: |
131/275 ;
131/352; 131/111 |
International
Class: |
A24B 13/00 20060101
A24B013/00; A24B 15/18 20060101 A24B015/18; A24B 15/30 20060101
A24B015/30; A24B 15/10 20060101 A24B015/10 |
Claims
1. A dissolvable-chewable tobacco tablet comprising: a solid
solution of soluble fiber and one or more sugar alcohols, the solid
solution having a glass transition temperature of less than
40.degree. C.; and tobacco dispersed in the solid solution such
that the tobacco is released from the tablet when the tablet is
chewed or dissolved within an oral cavity.
2. The tablet of claim 1, wherein the solid solution comprises at
least 20 weight percent of soluble fiber.
3. A dissolvable-chewable tobacco tablet comprising: a solid
solution comprising: at least 20 weight percent soluble fiber, and
at least 20 weight percent of one or more sugar alcohols; and
tobacco dispersed in the solid solution such that the tobacco is
released from the tablet when the tablet is chewed or dissolved
within an oral cavity.
4. The tablet of claim 3, wherein the solid solution has a glass
transition temperature of less than 40.degree. C.
5. The tablet of claim 1, wherein the solid solution has a glass
transition temperature of between -50.degree. C. and 40.degree.
C.
6. The tablet of claim 5, wherein the solid solution has a glass
transition temperature of between -20.degree. C. and 10.degree.
C.
7. The tablet of claim 1, further comprising oil dispersed in the
solid solution.
8. The tablet of claim 7, wherein the tablet comprises 2-15 weight
percent of oil.
9. The tablet of claim 7, wherein the oil is selected from the
group consisting of partially hydrogenated oil, palm kernel oil,
coconut oil, corn oil, cotton seed oil, olive oil, peanut oil,
canola oil, sesame oil, soybean oil, rapeseed oil, safflower oil,
sunflower oil, mustard oil, almond oil, beech nut oil, cashew oil,
hazelnut oil, macadamia oil, pecan oil, pine nut oil, pistachio
oil, walnut oil, grapefruit seed oil, lemon oil, orange oil,
pumpkin oil, watermelon seed oil, citrus oils, oils from melons and
gourd seeds, flaxseed oil, cocoa butter.
10. The tablet of claim 1, further comprising a plasticizer
dispersed in the solid solution, wherein the plasticizer comprises
propylene glycol, triacetin, glycerin, vegetable oil,
triglycerides, or a combination thereof.
11. The tablet of claim 1, wherein the soluble fiber is a dietary
fiber.
12. The tablet of claim 1, wherein the soluble fiber comprises
maltodextrin.
13. The tablet of claim 12, wherein the tablet comprises at least
20 weight percent maltodextrin.
14. The tablet of claim 1, wherein the soluble fiber comprises a
digestion resistant soluble fiber.
15. The tablet of claim 14, wherein the soluble fiber is a
digestion resistant maltodextrin.
16. The tablet of claim 1, wherein the one or more sugar alcohols
comprises is selected from the group consisting of mannitol,
sorbitol, xylitol, erythritol, isomalt, lactitol, maltitol,
maltitol syrup, and hydrogenated starch hydrolysates [HSH].
17. The tablet of claim 1, wherein the one or more sugar alcohols
comprise sorbitol.
18. The tablet of claim 1, wherein the one or more sugar alcohols
comprises mannitol.
19. The tablet of claim 1, further comprising an antioxidant.
20. The tablet of claim 1, the tablet having a water content of
between 0.5 weight percent and 7 weight percent.
21. The tablet of claim 1, wherein the tablet is shield shaped.
22. The tablet of claim 1, wherein the tablet is part of a sheet
structure configured for subdivision into individual tablets.
23. The tablet of claim 1, wherein the tobacco has a particle size
of 200 micrometers or less.
24. The tablet of claim 23, wherein the tobacco has a particle size
of between 25 micrometers and 125 micrometers.
25. The tablet of claim 1, wherein the tablet comprises at least 10
weight percent tobacco.
26. The tablet of claim 1, wherein the tablet comprises between 1
and 40 weight percent tobacco.
27. The tablet of claim 1, further comprising a color additive.
28. The tablet of claim 27, wherein the color additive is TiO2.
29. The tablet of claim 1, wherein the solid solution comprises
between 30 weight percent and 50 weight percent of soluble fiber
and between 30 weight percent and 50 weight percent of the one or
more sugar alcohols.
30. A method of forming a dissolvable-chewable tobacco tablet:
forming a molten mixture of soluble fiber, one or more sugar
alcohols, tobacco or a derivative thereof, and water while
maintaining a mixture temperature of less than 150.degree. C., the
molten mixture including at least 20 weight percent of soluble
fiber, at least 20 weight percent of one or more sugar alcohols,
and less than 15 weight percent water; and portioning the molten
mixture into a plurality of dissolvable-chewable tobacco
tablets.
31. The method of claim 30, wherein the molten mixture is formed in
an extruder.
32. The method of claim 30, further comprising mixing the molten
mixture with a plasticizer prior to portioning the molten mixture
into a plurality of tablets.
33. The method of claim 30, further comprising cutting the molten
mixture into individual tablets sized to be at least partially
received in an oral cavity of an adult tobacco consumer.
34. The method of claim 30, further comprising coating at least one
individual tablet.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority under 35
U.S.C. .sctn.119(e) to U.S. Application No. 61/886,325 filed Oct.
3, 2013. The prior application is incorporated herein by reference
in its entirety.
TECHNICAL FIELD
[0002] This document relates to dissolvable-chewable tobacco
tablets and methods for making dissolvable-chewable tobacco
tablets. For example, a dissolvable-chewable tobacco tablets can
include tobacco plant tissue within a solid solution of soluble
fiber and one or more sugar alcohols.
BACKGROUND
[0003] Tobacco can be enjoyed by adult tobacco consumers in a
variety of forms. Smoking tobacco is combusted and the aerosol
either tasted or inhaled (e.g., in a cigarette, cigar, or pipe).
Smokeless tobacco products are not combusted and include: chewing
tobacco, moist smokeless tobacco, snus, and ry snuff. Chewing
tobacco is coarsely divided tobacco leaf that is typically packaged
in a large pouch-like package and used in a plug or twist. Moist
smokeless tobacco is a moist, more finely divided tobacco that is
provided in loose form or in pouch form and is typically packaged
in round cans and used as a pinch or in a pouch placed between an
adult tobacco consumer's cheek and gum. Snus is a heat treated
smokeless tobacco. Dry snuff is finely ground tobacco that is
placed in the mouth or used nasally.
SUMMARY
[0004] A dissolvable-chewable tobacco tablet provided herein
provides a satisfying tactile and/or flavor experience. A
dissolvable-chewable tobacco tablet provided herein is at least
partially receivable in an oral cavity of an adult tobacco
consumer. In some cases, a dissolvable-chewable tobacco tablet
provided herein is wholly receivable in an oral cavity. A
dissolvable-chewable tobacco tablet provided herein can include a
solid solution of soluble fiber and one or more sugar alcohols with
tobacco plant tissue dispersed therein. In some cases, a
dissolvable-chewable tobacco tablet provided herein includes at
least 20 weight percent of soluble fiber. In some cases, soluble
fiber in dissolvable-chewable tobacco tablet provided herein can
include digestion-resistant maltodextrin. In some cases, a
dissolvable-chewable tobacco tablet provided herein includes at
least 20 weight percent of one or more sugar alcohols. A
dissolvable-chewable tobacco tablet provided herein can be adapted
to release the tobacco plant tissue therefrom when received within
the oral cavity of an adult tobacco consumer and/or chewed by an
adult tobacco consumer.
[0005] A dissolvable-chewable tobacco tablet provided herein can,
in some cases, includes between 1 and 40 weight percent tobacco
plant tissue. In some cases, the tobacco used in the
dissolvable-chewable tobacco tablet includes between 5 and 35
weight percent plant tissue. In some cases, the tobacco used in the
dissolvable-chewable tobacco tablet includes between 10 and 30
weight percent plant tissue. In some cases, the tobacco used in the
dissolvable-chewable tobacco tablet includes between 15 and 25
weight percent plant tissue. In some cases, the tobacco used in the
dissolvable-chewable tobacco tablet includes between 1 and 10
weight percent plant tissue. In some cases, tobacco plant tissue
used in a dissolvable-chewable tobacco tablet provided herein can
be processed to have an average particle size of less than 200
micrometers, less than 150 micrometers, less than 125 micrometers,
less than 100 micrometers, less than 75 micrometers, less than 50
micrometers, less than 25 micrometers, less than 20 micrometers, or
less than 10 micrometers. In some cases, tobacco plant tissue used
in a dissolvable-chewable tobacco tablet provided herein can be
processed to have an average particle size of at least 1
micrometer, at least 5 micrometers, at least 10 micrometers, at
least 25 micrometers, at least 50 micrometers, at least 75
micrometers, at least 100 micrometers, at least 125 micrometers, or
at least 150 micrometers. In some cases, tobacco plant tissue used
in a dissolvable-chewable tobacco tablet provided herein can be
processed to have an average particle size of between 25 and 125
micrometers.
[0006] A solid solution of soluble fiber and one or more sugar
alcohols provided herein can have a glass transition temperature
selected to provide a stable product at ambient temperatures, but
that is chewable at body temperature. For example, by using the
relatively high soluble fiber content, the glass transition
temperature of a dissolvable-chewable tobacco tablet provided
herein can be selected such that it is relatively close to ambient
temperature, which can permit an adult tobacco consumer to
experience an enjoyable tactile experience (e.g., mouth feel). A
dissolvable-chewable tobacco tablet provided herein can include a
single and continuous phase of the solid solution and dispersed
particles of tobacco plant tissue. At ambient temperatures, the
solid solution can be amorphous and glassy.
[0007] A method of making dissolvable-chewable tobacco tablets
provided herein includes forming a molten mixture of at least 20
weight percent soluble fiber, at least 20 weight percent of one or
more sugar alcohols, tobacco, and less than 15 weight percent water
while maintaining a mixture temperature of less than 150.degree. C.
and portioning the molten mixture into a plurality of
dissolvable-chewable tobacco tablets. In some cases, the
ingredients can be mixed to form the molten mixture in an extruder
and individual dissolvable-chewable tobacco tablets formed from the
molten mixture as it leaves the extruder. Plasticizers, such as
oil, can be added to the molten mixture (e.g., in an extruder). In
some cases, oil is added to increase the chewiness of a
dissolvable-chewable tobacco tablet provided herein. In some cases,
oil can be added to a molten mixture to cool the molten mixture to
a temperature such that the molten mixture becomes a solid solution
having some shape stability.
[0008] Unlike a traditional cooking process where sugars or sugar
alcohols are heated to a temperature such that caramelization and
other cross-linking occurs, methods provided herein include a
controlled mixing and heating of soluble fiber and sugar alcohols
to form a molten mixture and dispersing tobacco (and optionally
other ingredients) in the solid solution without creating
significant crosslinking of the sugar alcohols. Because tobacco
plant tissue can degrade when exposed to temperatures in excess of
150.degree. C., a temperature of a molten mixture provided herein
can be maintained at a temperature of 150.degree. C. or below. In
some cases, a molten mixture provided herein is heated to a maximum
temperature of between 80.degree. C. and 150.degree. C. In some
cases, a molten mixture provided herein is heated to a temperature
of between 100.degree. C. and 110.degree. C. When cooled ambient
temperatures, a molten mixture provided herein solidifies into an
amorphous, non-porous, glassy, body consisting of a single and
continuous phase of the solid solution and dispersed additives
(e.g., oil, tobacco fibers). Because the soluble fibers and sugar
alcohols do not become cross-linked, they can remain soluble and
thus dissolve when placed in an adult tobacco consumer's mouth.
[0009] In some cases, a dissolvable-chewable tobacco tablet
provided herein can include a digestion-resistant soluble fiber. In
some cases, a dissolvable-chewable tobacco tablet provided herein
can include a digestion-resistant maltodextrin derived from maze.
For example, Fibersol.RTM.-2 is a digestion-resistant corn-derived
maltodextrin soluble fiber, which can be used as the soluble fiber
in a dissolvable-chewable tobacco tablet provided herein
dissolvable-chewable tobacco tablet provided herein. Other starch
sources such as potato, rice, wheat, barley, peas, beans, lentils,
oats, or tapioca can be processed to form digestion-resistant
soluble fiber. A digestion resistant soluble fiber can include
starch linkages that remain undigested by enzymes of the human
digestive tract. Soluble fiber used in a dissolvable-chewable
tobacco tablet provided herein can be a soluble fiber generally
recognized as safe ("GRAS") by the Food and Drug Administration or
another appropriate private, state, or national regulatory
agency.
[0010] In some cases, a dissolvable-chewable tobacco tablet
provided herein can include one or more sugar alcohols selected
from the following group: mannitol, sorbitol, xylitol, erythritol,
isomalt, lactitol, maltitol, maltitol syrup, and hydrogenated
starch hydrolysates [HSH]. In some cases, a dissolvable-chewable
tobacco tablet provided herein can include two or more sugar
alcohols. In some cases, a dissolvable-chewable tobacco tablet
provided herein can include mannitol and sorbitol. Sugar alcohols
used in a dissolvable-chewable tobacco tablet provided herein can
be generally recognized as safe ("GRAS") by the Food and Drug
Administration or another appropriate private, state, or national
regulatory agency.
[0011] A dissolvable-chewable tobacco tablet provided herein can,
in some cases, include up to 15 weight percent water. In some
cases, a dissolvable-chewable tobacco tablet provided herein can
include between 0.5 weight percent and 7 weight percent water. In
some cases, a dissolvable-chewable tobacco tablet provided herein
can include between 1 weight percent and 5 weight percent water. In
some cases, a dissolvable-chewable tobacco tablet provided herein
can include between 2 weight percent and 4 weight percent
water.
[0012] A dissolvable-chewable tobacco tablet provided herein can
include a sweetener dispersed therein. Suitable sweeteners include
saccharine, sucralose, aspartame, acesulfame potassium, and
combinations thereof. In some cases, a dissolvable-chewable tobacco
tablet provided herein can be substantially free of sugars. For
example, a dissolvable-chewable tobacco tablet can be substantially
free of sugars, but include one or more sugar alcohols and
non-nutritive sweeteners. In some cases, a dissolvable-chewable
tobacco tablet provided herein can include non-caramelized sugars
in a percentage of no more than 25 weight percent.
[0013] A dissolvable-chewable tobacco tablet provided herein can
include flavorants. The flavorants can be natural or artificial.
Flavorants can be selected from the following: licorice,
wintergreen, cherry and berry type flavorants, Drambuie, bourbon,
scotch, whiskey, spearmint, peppermint, lavender, cinnamon,
cardamon, apium graveolents, clove, cascarilla, nutmeg, sandalwood,
bergamot, geranium, honey essence, rose oil, vanilla, lemon oil,
orange oil, Japanese mint, cassia, caraway, cognac, jasmin,
chamomile, menthol, ylang ylang, sage, fennel, pimenta, ginger,
anise, chai, coriander, coffee, mint oils from a species of the
genus Mentha, cocoa, and combinations thereof. Synthetic flavorants
can also be used. The particular combination of flavorants can be
selected from flavorants that are GRAS in a particular country,
such as the United States. Flavorants can also be included in the
dissolvable-chewable tobacco tablet as encapsulated flavorants.
[0014] A dissolvable-chewable tobacco tablet provided herein can
include a plasticizer dispersed in the solid solution. For example,
the plasticizer can be propylene glycol, triacetin, glycerin,
vegetable oil, triglycerides, or a combination thereof.
Plasticizers can be added as processing aids and/or to make a
dissolvable-chewable tobacco tablet chewier. In some cases, oil can
be added to a molten mixture including sugar alcohol(s), soluble
fibers, and tobacco to cool the molten mixture. In some cases, a
dissolvable-chewable tobacco tablet provided herein can include oil
dispersed within a matrix of a solid solution provided herein.
[0015] A body of a dissolvable-chewable tobacco tablet provided
herein can have a variety of different shapes, some of which
include disk, shield, heart, rectangle, and square. In some cases,
a body of a dissolvable-chewable tobacco tablet provided herein can
have rounded corners. In some cases, the body of the
dissolvable-chewable tobacco tablet can be spherical. According to
certain embodiments, the body can have a length or width of between
1 mm and 25 mm and a thickness of between 1 mm and 25 mm. In some
cases, the body can have a length or width of between 5 mm and 15
mm and a thickness of between 2 mm and 5 mm. In some cases, a
dissolvable-chewable tobacco tablet provided herein can include a
colorant. For example, a body of a dissolvable-chewable tobacco
tablet provided herein can include titanium dioxide, which can
provide the body with a white color. In some cases, a coating on
the body can include a colorant.
[0016] A method of forming dissolvable-chewable tobacco tablets can
include forming a molten mixture of at least 20 weight percent
soluble fiber, at least 20 weight percent of one or more sugar
alcohols, tobacco plant tissue (e.g., tobacco particles), and less
than 15 weight percent water, while maintaining a mixture
temperature of less than 150.degree. C. In some cases, the molten
mixture includes at less than 13 weight percent, less than 10
weight percent, less than 8 weight percent, less than 7 weight
percent, less than 6 weight percent, or less than 5 weight percent
water. In some cases, the molten mixture includes at least 0.5
weight percent, at least 1 weight percent, at least 2 weight
percent, or at least 3 weight percent water. In addition to
tobacco, water, sugar alcohol(s) and soluble fiber (e.g.,
maltodextrin), a molten mixture provided herein can include one or
more additives selected from colorants, sweeteners, flavorants,
plasticizers, antioxidants, processing aids, and combinations
thereof. In some cases, the molten mixture is substantially
sugars.
[0017] In some cases, the molten mixture provided herein is formed
in an extruder. The extruder can be a multi-staged extruder having
different sections that are heated to different temperatures and/or
have different ingredients introduced. In some cases, an extruder
provided herein can include multiple stages and can be used in a
method provided herein in a process where the maximum temperature
in any stage is no more than 150.degree. C. (e.g., no more than
120.degree. C., no more than 110.degree. C., or no more than
105.degree. C.). Portioning the molten mixture provided herein can
be accomplished using any suitable method. A method provided herein
can further include cooling dissolvable-chewable tobacco tablets
and packaging dissolvable-chewable tobacco tablets.
[0018] The details of one or more embodiments of the subject matter
described in this specification are set forth in the accompanying
drawings and the description below. Other features, aspects, and
advantages of the subject matter will become apparent from the
description, the drawings, and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a perspective view of a dissolvable-chewable
tobacco tablet provided herein.
[0020] FIGS. 1A-1O illustrates various additional exemplary shapes
of dissolvable-chewable tobacco tablets provided herein.
[0021] FIG. 2 depicts differential scanning calorimetry data for
sorbitol provided herein.
[0022] FIG. 3 depicts differential scanning calorimetry data for
maltodextrin provided herein.
[0023] FIG. 4 depicts differential scanning calorimetry data for
mannitol provided herein.
[0024] FIG. 5 is a process diagram for making dissolvable-chewable
tobacco tablets according to a method provided herein.
DETAILED DESCRIPTION
[0025] The dissolvable-chewable tobacco tablets described herein
include a solid solution of soluble fiber and one or more sugar
alcohols. Tobacco plant tissue (and optionally additional
additives) can be dispersed in the solid solution such that the
tobacco flavor, tobacco particles, and/or various additives are
released from the dissolvable-chewable tobacco tablet when the
dissolvable-chewable tobacco tablet is chewed and/or dissolved
within an adult tobacco consumer's oral cavity. The
dissolvable-chewable tobacco tablets described herein can provide a
favorable additive release profile and tactile experience. In some
cases, a dissolvable-chewable tobacco tablet provided herein
includes unbound tobacco in the solid solution. As used herein, the
term "tobacco plant tissue" refers to processed or non-processed
cellulosic parts (e.g., leaves, stems) of a member of the genus
Nicotiana, but does not include extracts of tobacco (e.g.,
tobacco-derived nicotine).
[0026] Unlike traditional cooking processes, which typically
solidify the ingredients by heating the ingredients to a
temperature such that sugars and/or sugar alcohols caramelize,
dissolvable-chewable tobacco tablets provided herein can be made by
forming a solid solution of soluble fiber and one or more sugar
alcohols in a controlled heating and mixing process maintained at a
temperature of 150.degree. C. or below. The solid solutions
described herein exhibit a glass transition temperature (Tg) in the
range of -75.degree. C. to 40.degree. C. Because tobacco
degradation can be accelerated when exposed to elevated
temperatures over extended periods of time, the temperature of a
molten mixture provided herein can be maintained at a temperature
of 150.degree. C. or below over a residence time of five to ten
minutes or less during the mixing (for example, if an extrusion
process is utilized). In some cases, an extruder can be used for
this controlled heating and mixing process. A desired texture of
the chewable dissolvable tablet can be determined by the selection
and weight percentages of the soluble fiber and sugar alcohol(s)
and the mixing process conditions. In some cases, a
dissolvable-chewable tobacco tablet provided herein can include
maltodextrin as the soluble fiber. In some cases, a
dissolvable-chewable tobacco tablet provided herein can include at
least 20 weight percent maltodextrin. In some cases, the soluble
fiber can be digestion resistant soluble fiber (e.g., digestion
resistant maltodextrin such as Fibersol.RTM.-2). By changing the
ratio of soluble fiber to sugar alcohols, the Tg of the mixture can
be altered and therefore the desired final texture of the product.
In some cases, plasticizers can be incorporated into a
dissolvable-chewable tobacco tablet provided herein to make it more
chewable.
[0027] In addition to tobacco, one or more additional additives can
be included in a dissolvable-chewable tobacco tablet provided
herein and adapted to be released from the dissolvable-chewable
tobacco tablet when the dissolvable-chewable tobacco tablet is
placed in an oral cavity and chewed by an adult tobacco
consumer.
[0028] A dissolvable-chewable tobacco tablet provided herein can
take up to 4 hours, up to 3 hours, up to 2 hours, or up to 1 hour
to dissolve when placed in an adult tobacco consumer's mouth.
Chewing can increase the rate of dissolution. In some cases, a
dissolvable-chewable tobacco tablet provided herein can take less
than 1 minute or up to 30 minutes to dissolve when placed in an
adult tobacco consumer's mouth. In some cases, a
dissolvable-chewable tobacco tablet provided herein can take
between 2 minutes and 15 minutes to dissolve when placed in an
adult tobacco consumer's mouth.
[0029] In addition to tobacco, sweeteners, and flavorants, a
dissolvable-chewable tobacco tablet provided herein can also
include fillers, plasticizers, and/or processing aids. Fillers can
also be included in the solid solution to alter the texture or
pliability of the dissolvable-chewable tobacco tablet. The solid
solution can also include plasticizers, which can increase the
softness and/or chewability of the dissolvable-chewable tobacco
tablet. Processing aids can also be present in the
dissolvable-chewable tobacco tablet and be used to facilitate
shaping processes.
Dissolvable-Chewable Tobacco Tablet Shapes and Packaging
[0030] FIG. 1 depicts an example of a dissolvable-chewable tobacco
tablet 110. Dissolvable-chewable tobacco tablet 110 has a shield
shape. For example, dissolvable-chewable tobacco tablet 110 can
have a length of about 16 mm, width of about 14 mm and a thickness
of about 9 mm.
[0031] Referring now to FIGS. 1A-1N, the dissolvable-chewable
tobacco tablet 110 can be molded into any desired shape. For
example, referring to FIGS. 1A-1L, dissolvable-chewable tobacco
tablets 110A-L can be formed in shapes that promotes improved
positioning in the oral cavity, improved packaging characteristics,
or both. In some circumstances, the dissolvable-chewable tobacco
tablet 110A-L can be configured to be: (A) an elliptical-shaped
dissolvable-chewable tobacco tablet 110A; (B) an elongated
elliptical-shaped dissolvable-chewable tobacco tablet 110B; (C)
semi-circular dissolvable-chewable tobacco tablet 110C; (D) square
or rectangular-shaped dissolvable-chewable tobacco tablet 110D; (E)
football-shaped dissolvable-chewable tobacco tablet 110E; (F)
elongated rectangular-shaped dissolvable-chewable tobacco tablet
110F; (G) boomerang-shaped dissolvable-chewable tobacco tablet
110G; (H) rounded-edge rectangular-shaped dissolvable-chewable
tobacco tablet 110H; (I) teardrop- or comma-shaped
dissolvable-chewable tobacco tablet 110I; (J) bowtie-shaped
dissolvable-chewable tobacco tablet 110J; (K) peanut-shaped
dissolvable-chewable tobacco tablet 110K; and (L) shield-shaped
dissolvable-chewable tobacco tablet. Alternatively, the
dissolvable-chewable tobacco tablet can have different thicknesses
or dimensionality, such that a beveled article (e.g., a wedge) is
produced (see, for example, product 110M depicted in FIG. 1M) or a
hemi-spherical shape is produced. In some cases, the
dissolvable-chewable tobacco tablet has a shield shape.
[0032] In addition or in the alternative to flavorants being
included within the soluble fiber matrix, flavorants can be
included on an exterior of the dissolvable-chewable tobacco tablet
110. For example, referring to FIG. 1N some embodiments of a
dissolvable-chewable tobacco tablet 110N can be equipped with
flavor strips 116.
[0033] Referring to FIG. 1O, particular embodiments of the
dissolvable-chewable tobacco tablet 110 can be embossed or stamped
with a design (e.g., a logo, an image, or the like). For example,
the dissolvable-chewable tobacco tablet 110O can be embossed or
stamped with any type of design 117 including, but not limited to,
a trademark, a product name, or any type of image. The design 117
can be formed directly into the dissolvable-chewable tobacco
tablet, arranged along the exterior of the product 110O. The design
117 can also be embossed or stamped into those embodiments with a
dissolvable film 116 applied thereto.
[0034] In some cases, the dissolvable-chewable tobacco tablet 110
can be wrapped or coated in an edible or dissolvable film, which
may be opaque, substantially transparent, or translucent. The
dissolvable film can readily dissipate when the
dissolvable-chewable tobacco tablet 110 is placed in an oral
cavity. In some cases, the dissolvable-chewable tobacco tablet 110
can be coated with a mouth-soluble material. Exemplary coating
materials include Carnuba wax, Beeswax, gelatin, acetylated
monoglyceride, starch (e.g., native potato starch, high amylose
starch, and hydroxypropylated potato starch), Zein, Shellac, ethyl
cellulose, methylcellulose, hydroxypropyl methylcellulose,
carboxymethyl cellulose, and combinations thereof. Additives, such
as miglycol, titanium dioxide, kaoline, bentonite, can be
incorporated into the coating material to improve oxygen or
moisture barrier and mechanical properties for the coating or film.
For example, a coating can include a combination of gelatin,
methylcellulose, or gelatin and hydroxymethylcellulose. In some
cases, the coating can contain sugar alcohols such as sorbitol,
mannitol, xylitol, erythritol), disaccharide-derived (e.g.,
isomalt, lactitol, maltitol), or polysaccharide-derived mixtures
(e.g., maltitol syrup, hydrogenated starch hydrolysates [HSH]) or
combinations thereof. In some cases a coating material can contain
sugar alcohols and hydroxymethylcellulose, gelatin, wax, with
additives. In some cases, a coating material can include a
plasticizer. In some cases, a coating can include a colorant, a
flavorant, and/or a one or more of the additives discussed above.
In some cases, the solid solution can form a body that can have
surfaces roughened to improve the adherence of a coating. In some
cases, a coating can provide a glossy or semi-glossy appearance, a
smooth surface, and/or an appealing visual aesthetic (e.g., a nice
color). In some cases, the coating (e.g., a Beeswax, Carnuba wax,
Zein, acetylated monoglyceride, and/or hydroxypropylated potato
starch coating) can provide a soft mouth feel. In some cases, the
coating (e.g., a methylcellulose, hydroxypropyl methylcellulose,
carboxymethyl cellulose, ethyl cellulose, and/or gelatin coating)
can provide a hard outer coating.
[0035] One or more dissolvable-chewable tobacco tablets 110 can be
packaged in a variety of conventional and non-conventional manners.
For example, a plurality of dissolvable-chewable tobacco tablets
110 can be packaged in a container having a lid. In some cases, a
plurality of dissolvable-chewable tobacco tablets 110 can be
stacked and packaged in a paper, plastic, and/or aluminum foil
tube. The packaging can have a child-resistant lid.
Dissolvable-Chewable Tobacco Tablet Properties
[0036] The dissolvable-chewable tobacco tablet 110 can provide a
favorable tactile experience (e.g., mouth feel). While the
dissolvable-chewable tobacco tablet 110 can retain its shape during
processing, shipping, handling, the dissolvable-chewable tobacco
tablet 110 includes a solid solution that dissolves or
disintegrates when the dissolvable-chewable tobacco tablet 110 is
placed in an oral cavity, exposed to saliva, and/or chewed. Prior
to dissolution or disintegration, the dissolvable-chewable tobacco
tablet 110 in an oral cavity undergoes a phase transition from a
glassy state to a rubbery state then finally into to a viscous
state. To further promote a favorable tactile experience (e.g.,
mouth feel), in some cases, dissolvable-chewable tobacco tablet 110
can be formulated to exhibit a smooth texture. Working of the
dissolvable-chewable tobacco tablet 110 within the oral cavity can
accelerate the release of the tobacco within the solid
solution.
[0037] During use, the environment surrounding the
dissolvable-chewable tobacco tablet 110 transitions from room
temperature (e.g., .about.25.degree. C.) to body temperature (e.g.,
.about.37.degree. C.). One way of characterizing the properties of
the dissolvable-chewable tobacco tablet 110 is by determining the
phase transition points of the dissolvable-chewable tobacco tablet
using differential scanning calorimetry (DSC). The
dissolvable-chewable tobacco tablet 110 is composed of various
ingredients, therefore, the thermal transitions of the
dissolvable-chewable tobacco tablet can differ not only due to the
individual properties of each ingredient, but also due to the
ratios of those ingredients. For example, the thermal transitions
of a dissolvable-chewable tobacco tablet with approximately 30-40
weight percent of maltodextrin, a mixture of mannitol and sorbitol
approximately 30-40 weight percent, and water content from 0.5
weight percent to 7 weight percent. In some cases, a glass
transition temperature (Tg) 202 of the dissolvable-chewable tobacco
tablet 110 can be from -65.degree. C. to 60.degree. C. (e.g.,
-50.degree. C. to 40.degree. C., -40.degree. C. to 30.degree. C.,
-30.degree. C. to 20.degree. C., -20.degree. C. to 10.degree. C.,
and -10.degree. C. to 0.degree. C.). The approximate Tg of this
formulation can be from -20 to 10.degree. C. Thus, at room
temperature the dissolvable-chewable tobacco tablet 110 is at the
end of the transition from a glassy state to a rubbery/viscous
state. Once the dissolvable-chewable tobacco tablet 110 is placed
in an oral cavity at body temperature, the dissolvable-chewable
tobacco tablet 110 can complete the phase transition to a
rubbery/viscous state. In particular embodiments, the
dissolvable-chewable tobacco tablet 110 is coated to facilitate
bulk packaging.
[0038] In some cases, the melting transition point (Tm) of the oil
dispersed in the dissolvable-chewable tobacco tablet 110 is
28.degree. C. (82.4.degree. F.). As the dissolvable-chewable
tobacco tablet 110 is exposed to body temperature that exceeds the
Tm of the oil, the oil undergoes a phase transition to a liquid
state. This transition can provide a favorable tactile experience
(e.g., mouth feel) to the user as it causes the
dissolvable-chewable tobacco tablet to soften. Referring to FIG. 2,
the DSC for pure mannitol with a melting temperature at 166.degree.
C. is shown. The mannitol peak at 166.degree. C. can be absent in
the DSC of the solid mixture. FIG. 3 shows the DSC for pure
maltodextrin as a reference sample. The mixture of mannitol,
sorbitol and maltodextrin can be amorphous. Therefore the product
does not have "crumbly" texture in the chewable product. The
multiple phases in the dissolvable-chewable tobacco tablet are
visible through x-ray microtomography. A soluble fiber, sugar
alcohol, and tobacco mixture appears as a dense matrix domain,
while the oil is partitioned in the oil domains.
[0039] The dissolvable-chewable tobacco tablet 110 can have a
variety of colors. In some cases, the dissolvable-chewable tobacco
tablet 110 has an off-white color. For example, Titanium dioxide
(TiO2) can be added to the soluble fiber and sugar alcohol mixture.
In a scanning electron microscope image, the dark voids dispersed
throughout the dense matrix can indicate pockets of oil, flavor. In
some cases, natural and artificial coloring can be added to a
molten mixture that forms the solid solution during a molding
process to form dissolvable-chewable tobacco tablets 110 having a
predetermined color. Encapsulated flavors can be added during the
extrusion process to create speckles, patterns, or dots within a
dissolvable-chewable tobacco tablet.
Soluble Fiber
[0040] Soluble fiber dissolves in ambient water. Insoluble fiber
does not dissolve in ambient water. Soluble fibers can attract
water and form a gel. Not only are many soluble fibers safe for
consumption, but some soluble fibers are used as a dietary
supplement. As a dietary supplement, soluble fiber can slow down
digestion and delay the emptying of a stomach. Instead of using
soluble fiber as a mere additive, however, dissolvable-chewable
tobacco tablets provided herein include a solid solution of soluble
fiber and sugar alcohols that can be combined with tobacco (and
optionally other additives) to provide a satisfying tactile and/or
flavor experience.
[0041] Any suitable soluble fiber or combination of soluble fibers
can be used to form a soluble-fiber solution provided herein.
Suitable soluble fibers include maltodextrin, psyllium, pectin,
guar gum, gum arabic, inulin, arabinoxylans, cellulose, and many
other plant components such as resistant starch, resistant
dextrins, lignin, pectins, beta-glucans, and oligosaccharides or a
combination thereof. In some cases, a dissolvable-chewable tobacco
tablet provided herein can include a digestion-resistant soluble
fiber. A digestion resistant soluble fiber can include starch
linkages that remain undigested by enzymes of the human digestive
tract. In some cases, a dissolvable-chewable tobacco tablet
provided herein can include a digestion-resistant maltodextrin. In
some cases, a digestion-resistant maltodextrin can be derived from
maze. Suitable maltodextrins can include those that are soluble in
water up to 70% at 20.degree. C., have a viscosity of about 15 cps
for a 30% solution at 30.degree. C., a DE in the range of about
6-16, and contain random .alpha.-1,2, .alpha.-1,3, .alpha.-1,4,
.beta.-1,2, .beta.-1,3 and .beta.-1,4 glucose linkages in addition
to the normal .alpha.-1,4 glucose linkages found in partially
hydrolyzed starch. See, e.g., U.S. Pat. Nos. 5,410,035; 5,380,717,
which are hereby incorporated by reference. For example,
Fibersol.RTM.-2 is a maltodextrin of DE 6-10 processed from corn
starch using hydrochloric acid and enzymes, which can be used as
the soluble fiber in a tobacco tablet provided herein.
Fibersol.RTM.-2 is partially indigestible because human digestive
enzymes are incapable of digesting .beta. 1,2, .beta. 1,3 and
.beta. 1,6 glucose bonds. See, e.g., U.S. Pat. No. 6,203,842, which
is hereby incorporated by reference. Other starch sources such as
potato, rice, wheat, barley, peas, beans, lentils, oats, or tapioca
can be processed to form digestion-resistant soluble fiber. A
digestion resistant soluble fiber includes starch linkages that
cannot be hydrolyzed by enzymes of the human digestive tract. In
some cases, suitable soluble fibers include Pinefibre, Pinefibre C,
Dexflow and Pineflow as discussed in U.S. Pat. No. 5,236,719, which
is hereby incorporated by reference. Soluble fiber used in a
dissolvable-chewable tobacco tablet provided herein can be GRAS by
the Food and Drug Administration or another appropriate private,
state, or national regulatory agency.
[0042] A dissolvable-chewable tobacco tablet provided herein can
include at least 20 weight percent of soluble fiber, at least 25
weight percent of soluble fiber, at least 30 weight percent of
soluble fiber, at least 35 weight percent of soluble fiber, at
least 40 weight percent of soluble fiber, at least 45 weight
percent of soluble fiber, at least 50 weight percent of soluble
fiber, or at least 55 weight percent of soluble fiber. In some
cases, a dissolvable-chewable tobacco tablet provided herein can
include at least 20 weight percent maltodextrin, at least 25 weight
percent maltodextrin, at least 30 weight percent maltodextrin, at
least 35 weight percent maltodextrin, at least 40 weight percent
maltodextrin, at least 45 weight percent maltodextrin, at least 50
weight percent maltodextrin, or at least 55 weight percent
maltodextrin. In some cases, a dissolvable-chewable tobacco tablet
provided herein can include less than 70 weight percent
maltodextrin, less than 60 weight percent maltodextrin, less than
50 weight percent maltodextrin, or less than 40 weight percent
maltodextrin. In some cases, a dissolvable-chewable tobacco tablet
provided herein can include at least 20 weight percent
digestion-resistant maltodextrin, at least 25 weight percent
digestion-resistant maltodextrin, at least 30 weight percent
digestion-resistant maltodextrin, at least 35 weight percent
digestion-resistant maltodextrin, at least 40 weight percent
digestion-resistant maltodextrin, at least 45 weight percent
digestion-resistant maltodextrin, at least 50 weight percent
digestion-resistant maltodextrin, or at least 55 weight percent
digestion-resistant maltodextrin.
Sugar Alcohol(s)
[0043] Sugar alcohols, also known as polyols or polyhydric
alcohols, are hydrogenated carbohydrates that can be used as sugar
replacers. Sugar alcohols are non-cariogenic, low-glycemic,
low-energy, low-insulinemic, low digestible, osmotic, carbohydrates
that dissolve in water. Sugar alcohols can be used in comestible
products to take advantage of these various properties. For
example, sugar alcohols can be used to replace sugar because sugar
alcohols contain fewer calories per gram than sugar and sugar
alcohols do not cause tooth decay. A chewable digestible tobacco
tablet described herein can include at least one sugar alcohol
combined with soluble fiber to provide a solid solution that can
hold tobacco (and other optional additive) to provide a satisfying
tactile and/or flavor experience.
[0044] Any suitable sugar alcohol can be used in a solid solution
provided herein. Suitable sugar alcohols used in a
dissolvable-chewable tobacco tablet provided herein can be
monosaccharide-derived (e.g., sorbitol, mannitol, xylitol,
erythritol), disaccharide-derived (e.g., isomalt, lactitol,
maltitol), or polysaccharide-derived mixtures (e.g., maltitol
syrup, hydrogenated starch hydrolysates [HSH]. Sugar alcohols used
in a dissolvable-chewable tobacco tablet provided herein can be a
sugar alcohol generally recognized as safe ("GRAS") or approved
food additives by the Food and Drug Administration or another
appropriate private, state, or national regulatory agency.
[0045] A dissolvable-chewable tobacco tablet provided herein can
include at least 20 weight percent of one or more sugar alcohols,
at least 25 weight percent of one or more sugar alcohols, at least
30 weight percent of one or more sugar alcohols, at least 35 weight
percent of one or more sugar alcohols, at least 40 weight percent
of one or more sugar alcohols, at least 45 weight percent of one or
more sugar alcohols, at least 50 weight percent of sugar alcohol,
or at least 55 weight percent of one or more sugar alcohols. In
some cases, a dissolvable-chewable tobacco tablet provided herein
can include less than 75 weight percent of one or more sugar
alcohols, less than 60 weight percent of one or more sugar
alcohols, or less than 50 weight percent of one or more sugar
alcohols. In some cases, a dissolvable-chewable tobacco tablet
provided herein can include at least 2 weight percent sorbitol, at
least 5 weight percent sorbitol, at least 10 weight percent
sorbitol, at least 15 weight percent sorbitol, at least 20 weight
percent sorbitol, at least 25 weight percent sorbitol, at least 30
weight percent sorbitol, or at least 35 weight percent sorbitol. In
some cases, a dissolvable-chewable tobacco tablet provided herein
can include at least 2 weight percent mannitol, at least 5 weight
percent mannitol, at least 10 weight percent mannitol, at least 15
weight percent mannitol, at least 20 weight percent mannitol, at
least 25 weight percent mannitol, at least 30 weight percent
mannitol, or at least 35 weight percent mannitol.
Tobacco
[0046] Tobacco plant tissue (e.g., tobacco particles) can be mixed
with the solid solution during an extrusion process. Tobacco plant
tissue can provide passages in the dissolvable-chewable tobacco
tablet, which can permit certain tobacco constituents and/or
additives within the dissolvable-chewable tobacco tablet to be
released into an oral cavity when the dissolvable-chewable tobacco
tablet is received in an oral cavity and/or chewed.
[0047] Suitable tobaccos include fermented and unfermented
tobaccos. In addition to fermentation, the tobacco can be processed
using other techniques. For example, tobacco can be processed by
heat treatment (e.g., cooking, toasting), flavoring, enzyme
treatment, expansion and/or curing. Both fermented and
non-fermented tobaccos can be processed using these techniques. In
other embodiments, the tobacco can be unprocessed tobacco. Specific
examples of suitable processed tobaccos include dark air-cured,
dark fire cured, burley, flue cured, and cigar filler or wrapper,
as well as the products from the whole leaf stemming operation. In
some embodiments, the tobacco fibers includes up to 70% dark
tobacco on a fresh weight basis. For example, tobacco can be
conditioned by heating, sweating, and/or pasteurizing steps as
described in U.S. Publication Nos. 2004/0118422 or 2005/0178398,
each of which is hereby incorporated by reference. Fermenting
typically is characterized by high initial moisture content, heat
generation, and a 10 to 20% loss of dry weight. See, e.g., U.S.
Pat. Nos. 4,528,993; 4,660,577; 4,848,373; and 5,372,149; each of
which is hereby incorporated by reference. In addition to modifying
the aroma of the leaf, fermentation can change either or both the
color and texture of a leaf. Also during the fermentation process,
evolution gases can be produced, oxygen can be taken up, the pH can
change, and the amount of water retained can change. See, for
example, U.S. Publication No. 2005/0178398 and Tso (1999, Chapter 1
in Tobacco, Production, Chemistry and Technology, Davis &
Nielsen, eds., Blackwell Publishing, Oxford), each of which is
hereby incorporated by reference. Cured, or cured and fermented
tobacco can be further processed (e.g., cut, expanded, blended,
milled or comminuted) prior to incorporation into the oral tobacco
product. The tobacco, in some embodiments, is long cut fermented
cured moist tobacco having an oven volatiles content of between 48
and 50 weight percent prior to mixing with the mouth-stable polymer
and optionally flavorants and other additives.
[0048] The tobacco can, in some embodiments, be prepared from
plants having less than 20 .mu.g of DVT per cm.sup.2 of green leaf
tissue. For example, the tobacco fibers can be selected from the
tobaccos described in U.S. Patent Publication No. 2008/0209586,
which is hereby incorporated by reference. Tobacco compositions
containing tobacco from such low-DVT varieties exhibits improved
flavor characteristics in sensory panel evaluations when compared
to tobacco or tobacco compositions that do not have reduced levels
of DVTs.
[0049] Green leaf tobacco can be cured using conventional means,
e.g., flue-cured, barn-cured, fire-cured, air-cured or sun-cured.
See, for example, Tso (1999, Chapter 1 in Tobacco, Production,
Chemistry and Technology, Davis & Nielsen, eds., Blackwell
Publishing, Oxford) for a description of different types of curing
methods. Cured tobacco is usually aged in a wooden drum (i.e., a
hogshead) or cardboard cartons in compressed conditions for several
years (e.g., two to five years), at a moisture content ranging from
10% to about 25%. See, U.S. Pat. Nos. 4,516,590 and 5,372,149, each
of which is hereby incorporated by reference. Cured and aged
tobacco then can be further processed. Further processing includes
conditioning the tobacco under vacuum with or without the
introduction of steam at various temperatures, pasteurization, and
fermentation. Fermentation typically is characterized by high
initial moisture content, heat generation, and a 10 to 20% loss of
dry weight. See, e.g., U.S. Pat. Nos. 4,528,993, 4,660,577,
4,848,373, 5,372,149; U.S. Publication No. 2005/0178398; and Tso
(1999, Chapter 1 in Tobacco, Production, Chemistry and Technology,
Davis & Nielsen, eds., Blackwell Publishing, Oxford), each of
which is hereby incorporated by reference. Cured, aged, and
fermented tobacco can be further processed (e.g., cut, shredded,
expanded, or blended). See, for example, U.S. Pat. Nos. 4,528,993;
4,660,577; and 4,987,907; each of which is hereby incorporated by
reference.
[0050] Tobacco plant tissue can be processed to a desired size
(e.g., a desired particle size). In some cases, the tobacco fiber
can be processed to have an average fiber size of less than 200
micrometers, less than 150 micrometers, less than 125 micrometers,
less than 100 micrometers, less than 75 micrometers, less than 50
micrometers, less than 25 micrometers, less than 20 micrometers, or
less than 10 micrometers. In some cases, tobacco plant tissue used
in a dissolvable-chewable tobacco tablet provided herein can be
processed to have an average particle size of at least 1
micrometer, at least 5 micrometers, at least 10 micrometers, at
least 25 micrometers, at least 50 micrometers, at least 75
micrometers, at least 100 micrometers, at least 125 micrometers, or
at least 150 micrometers. In some cases, tobacco plant tissue used
in a dissolvable-chewable tobacco tablet provided herein can be
processed to have an average particle size of between 25 and 125
micrometers. In some embodiments, the tobacco fibers includes long
cut tobacco, which can be cut or shredded into widths of about 10
cuts/inch up to about 110 cuts/inch and lengths of about 0.1 inches
up to about 1 inch. Double cut tobacco fibers can have a range of
particle sizes such that about 70% of the double cut tobacco fibers
fall between the mesh sizes of 20 mesh and 80 mesh.
[0051] Tobacco plant tissue used in a dissolvable-chewable tobacco
tablet provided herein can have a total oven volatiles content of
about 10% by weight or greater; about 20% by weight or greater;
about 40% by weight or greater; about 15% by weight to about 25% by
weight; about 20% by weight to about 30% by weight; about 30% by
weight to about 50% by weight; about 45% by weight to about 65% by
weight; or about 50% by weight to about 60% by weight. Those of
skill in the art will appreciate that "moist" tobacco typically
refers to tobacco that has an oven volatiles content of between
about 40% by weight and about 60% by weight (e.g., about 45% by
weight to about 55% by weight, or about 50% by weight). As used
herein, "oven volatiles" are determined by calculating the
percentage of weight loss for a sample after drying the sample in a
pre-warmed forced draft oven at 110.degree. C. for 3.25 hours. The
dissolvable-chewable tobacco tablet can have a different overall
oven volatiles content than the oven volatiles content of the
tobacco fibers used to make the oral tobacco product. The
processing steps described herein can reduce or increase the oven
volatiles content.
Additives
[0052] A variety of additives can be included in a
dissolvable-chewable tobacco tablet provided herein. The additives
can include non-nicotine alkaloids, minerals, vitamins, dietary
supplements, nutraceuticals, energizing agents, soothing agents,
coloring agents, amino acids, chemsthetic agent, antioxidants, food
grade emulsifiers, pH modifiers, botanicals (e.g., green tea),
teeth whitening (e.g., SHMP), therapeutic agents, sweeteners,
flavorants, and combinations thereof.
Antioxidants
[0053] A dissolvable-chewable tobacco tablet 110 provided herein
can include one or more antioxidants. In some cases, a
dissolvable-chewable tobacco tablet provided herein can include
0.01 and 5.00 weight percent antioxidant, between 0.05 and 1.0
weight percent antioxidant, between 0.10 and 0.75 weigh percent
antioxidant, or between 0.15 and 0.5 weight percent antioxidant.
Suitable examples of antioxidants include ascorbyl palmitate (a
vitamin C ester), BHT, ascorbic acid (Vitamin C), and sodium
ascorbate (Vitamin C salt). In some cases, monosterol citrate,
tocopherols, propyl gallate, tertiary butylhydroquinone (TBHQ),
butylated hydroxyanisole (BHA), Vitamin E, or a derivative thereof
can be used as the antioxidant. For example, ascorbyl palmitate can
be the antioxidant in the formulations listed in Table I.
Antioxidants can be incorporated into the solid solution during a
mixing process (e.g., added to an extruder mixing the
ingredients).
[0054] The presence of antioxidants may also reduce the formation
of other tobacco derived impurities, such as Cotinine and
myosime.
[0055] Sweeteners
[0056] A variety of synthetic and/or natural sweeteners can be used
as additives in the dissolvable-chewable tobacco tablet 110.
Suitable natural sweeteners include sugars, for example,
monosaccharides, disaccharides, and/or polysaccharide sugars,
and/or mixtures of two or more sugars. According to some
embodiments, the dissolvable-chewable tobacco tablet 110 includes
one or more of the following: sucrose or table sugar; honey or a
mixture of low molecular weight sugars not including sucrose;
glucose or grape sugar or corn sugar or dextrose; molasses; corn
sweetener; corn syrup or glucose syrup; fructose or fruit sugar;
lactose or milk sugar; maltose or malt sugar or maltobiose; sorghum
syrup; mannitol or manna sugar; sorbitol or d-sorbite or d-sobitol;
fruit juice concentrate; and/or mixtures or blends of one or more
of these ingredients. A dissolvable-chewable tobacco tablet
provided herein can also include non-nutritive sweeteners. Suitable
non-nutritive sweeteners include stevia, saccharin; aspartame;
sucralose; or acesulfame potassium.
[0057] Flavorants
[0058] The dissolvable-chewable tobacco tablet 110 can optionally
include one or more flavorants. The flavorants can be natural or
artificial. For example, suitable flavorants include wintergreen,
cherry and berry type flavorants, various liqueurs and liquors
(such as Dramboui, bourbon, scotch, and whiskey) spearmint,
peppermint, lavender, cinnamon, cardamon, apium graveolents, clove,
cascarilla, nutmeg, sandalwood, bergamot, geranium, honey essence,
rose oil, vanilla, lemon oil, orange oil, Japanese mint, cassia,
caraway, cognac, jasmin, chamomile, menthol, ylang ylang, sage,
fennel, pimenta, ginger, anise, chai, coriander, coffee, liquorish,
and mint oils from a species of the genus Mentha, and encapsulated
flavors. Mint oils useful in particular, embodiments of the
dissolvable-chewable tobacco tablet 110 include spearmint and
peppermint. Synthetic flavorants can also be used. The particular
combination of flavorants can be selected from flavorants that are
GRAS in a particular country, such as the United States. Flavorants
can also be included in the dissolvable-chewable tobacco tablet as
encapsulated flavorants.
[0059] In some cases, the flavorants in the dissolvable-chewable
tobacco tablet 110 are limited to less than 20 weight percent in
sum. In some cases, the flavorants in the dissolvable-chewable
tobacco tablet 110 are limited to be less than 10 weight percent in
sum. For example, certain flavorants can be included in the
dissolvable-chewable tobacco tablet 110 in amounts of about 1
weight percent to 5 weight percent.
[0060] Other Additives
[0061] Dissolvable-chewable tobacco tablets provided herein may
optionally include additives in addition to tobacco. For example,
these additives can further include non-tobacco alkaloids, dietary
minerals, vitamins, dietary supplements, therapeutic agents, and
fillers.
[0062] Dissolvable-chewable tobacco tablets provided herein can
also include vitamins, dietary minerals, other dietary supplements,
and/or therapeutic agents. For example, suitable vitamins include
Vitamins A, B1, B2, B6, C, D2, D3, E, F, and K. For example, a
dissolvable-chewable tobacco tablet 110 can include C-vitamins with
or without the presence of tobacco. Suitable dietary minerals
include calcium (as carbonate, citrate, etc.) or magnesium (as
oxide, etc.), chromium (usually as picolinate), and iron (as
bis-glycinate). One or more dietary minerals could be included in a
dissolvable-chewable tobacco tablet with or without the use of
other additives. Other dietary supplements and/or therapeutic
agents can also be included as additives.
[0063] The dissolvable-chewable tobacco tablet provided herein can
also include fillers such as starch, di-calcium phosphate, lactose,
sorbitol, mannitol, and microcrystalline cellulose, calcium
carbonate, dicalcium phosphate, calcium sulfate, clays, silica,
sodium lauryl sulfate (SLS), glyceryl palmitostearate, sodium
benzoate, sodium stearyl fumarate, talc, and stearates (e.g., Mg or
K), and waxes (e.g., glycerol monostearate, propylene glycol
monostearate, and acetylated monoglycerides), stabilizers (e.g.,
ascorbic acid and monosterol citrate, BHT, or BHA), disintegrating
agents (e.g., starch, sodium starch glycolate, cross caramellose,
cross linked PVP), pH stabilizers, or preservatives. In some cases,
an amount of filler in the dissolvable-chewable tobacco tablet 110
is limited to less than 10 weight percent in sum. In some cases, an
amount of filler in the dissolvable-chewable tobacco tablet 110 is
limited to be less than 5 weight percent in sum. In some cases,
fillers can dissolve or disintegrate during use and thus result in
a dissolvable-chewable tobacco tablet that becomes more pliable
during use.
Plasticizers
[0064] Dissolvable-chewable tobacco tablets provided herein can
also include one or more plasticizers. Plasticizers can soften the
final dissolvable-chewable tobacco tablet and thus increase its
flexibility. Suitable plasticizers include propylene glycol,
triacetin, glycerin, vegetable oil, partially hydrogenated oil,
triglycerides, triacetin, medium chain triglycerides, and
combinations thereof. In some cases, the plasticizer can include
phthalates. Esters of polycarboxylic acids with linear or branched
aliphatic alcohols of moderate chain length can also be used as
plasticizers. Moreover, plasticizers can facilitate the extrusion
processes described below. In some cases, the dissolvable-chewable
tobacco tablet 110 can include up to 20 weight percent plasticizer.
In some cases, a dissolvable-chewable tobacco tablet provided
herein includes between 0.05 and 10 weight percent plasticizer,
between 1 and 8 weight percent plasticizer, or between 2 and 4
weight percent plasticizer. For example, a dissolvable-chewable
tobacco tablet provided herein can include about 3 to 6.5 weight
percent of propylene glycol.
Molding Processes
[0065] Dissolvable-chewable tobacco tablets provided herein can be
produced by forming a molten mixture of soluble fiber, sugar
alcohols (e.g., sorbitol and mannitol), and tobacco and shaping
that molten mixture into individual dissolvable-chewable tobacco
tablets. The molten mixture is formed under controlled heating
conditions such that a solution of soluble fiber, sugar alcohol(s),
water, and tobacco is formed without degrading the tobacco or
creating cross-linking between the sugar alcohol(s) and/or the
soluble fiber. In some cases, a temperature of the molten mixture
is maintained at a temperature below 150.degree. C. In some cases,
a rod or sheet of the molten mixture is extruded and cut into
individual dissolvable-chewable tobacco tablets. In some cases, a
molten mixture of soluble fiber, sugar alcohol(s), and tobacco can
be injection molded, compression molded, or injection-compression
molded
[0066] Cooking processes forming dissolvable edible products
sometimes utilize the cross-linking of sugars or sugar alcohols
that occurs after heating to caramelization temperatures. Such
heating results in a desirable caramelization of the product. The
relatively high temperatures required for caramelization, however,
can accelerate the degradation of exhausted-tobacco because of the
high temperatures and other factors (e.g., residence time during
extrusion). Because tobacco degradation can be accelerated when
exposed to elevated temperatures over extended periods of time, the
temperature of a molten mixture provided herein can be maintained
at a temperature of 150.degree. C. or below over a processing time
(e.g., a residence time of five to ten minutes or less if an
extrusion process is utilized). In some cases, a molten mixture
provided herein is heated to a temperature of between 80.degree. C.
and 150.degree. C. In some cases, a molten mixture provided herein
is heated to a temperature of between 100.degree. C. and
110.degree. C. When cooled below its glass transition temperature,
a molten mixture provided herein solidifies into an amorphous,
non-porous, soluble fiber matrix containing tobacco. A solid
solution of tobacco and sugar alcohol(s), however, can provide a
dissolvable-chewable tobacco tablet provided herein with a suitable
dissolution time when place in an adult consumer's mouth. A
dissolvable-chewable tobacco tablet provided herein can also be
chewable.
[0067] A molten mixture can be mixed and heated in any suitable but
controlled method. In some cases, such as shown in FIG. 5,
ingredients for a molten mixture can be combined in an extruder and
mixed in a continuous extrusion process. Unlike a traditional
cooking method, dissolvable-chewable tobacco tablet provided herein
can have attributes precisely controlled by extruder operation
parameters, such as feed rate, barrel temperature profile, screw
design, rpms, etc.
[0068] Water added to molten mixture can be maintained at a
percentage of less than 15 weight percent. A water content of a
dissolvable-chewable tobacco tablet provided herein can be
controlled in the extrusion process to ensure that the molten
mixture becomes a solid solution. In some cases, a molten mixture
can have a water content of less than 15 weight percent. In some
cases, water content in a dissolvable-chewable tobacco tablet
provided herein ranges from 0.5 weight percent to 7 weight percent.
In some cases, water content in a dissolvable-chewable tobacco
tablet provided herein ranges from 1 weight percent to 5 weight
percent.
[0069] Referring to the extrusion process 500 illustrated in FIG.
5, soluble fibers (e.g., maltodextrin or digestion resistant
maltodextrin), sugar alcohol or blend of multiple sugar alcohols
(e.g., sorbitol and mannitol), and color (e.g., TiO2) 502 can be
introduced into the extrusion process 500 and can undergo a powder
mixing 504 for a period of time before progressing to the extruder
516. A mixing extruder 516 can include multiple stages controlled
to be maintained at a predetermined temperature. As shown, extruder
516 can include stages having temperatures ranging between
80.degree. C. and 150.degree. C. For example, an extruder can have
seven stages with each stage controlled to a specific temperature
(e.g., some stages range between 80.degree. C. and 100.degree. C.,
from 100.degree. C. and 110.degree. C., from 100.degree. C. and
110.degree. C., from 100.degree. C. and 130.degree. C., from
100.degree. C. and 130.degree. C., from 100.degree. C. and
130.degree. C., from 80.degree. C. and 120.degree. C.). A mixture
of sweetener and water can also be introduced 506 into the process
500 and can undergo a solution mixing step 508 for a period of time
before progressing to the extruder 516. Any combination of tobacco,
flavor, propylene glycol, and antioxidants can also be introduced
510 into the process 500 and can undergo a solution mixing step 512
for a period of time before progressing to the extruder 516. In
some cases, this process allows tobacco to be incorporated into the
process with minimum exposure to temperature and air. A plasticizer
(e.g., partially hydrogenated vegetable oil) can also undergo a
solution mixing step 514 for a period of time before progressing
into the extruder 516. The extruder 516 can maintain a warm
internal temperature (e.g., between approximately 80.degree. C. to
150.degree. C.). The low temperature of the extruder 516 has the
advantage of reducing undesirable degradation of additives (e.g.,
tobacco) and cross-linking of the sugar alcohol(s). The molten
mixture can exit the extruder 516 and be allowed to cool (e.g., to
ambient temperature) to form a viscous material including a solid
solution of tobacco fiber, sugar alcohol(s), and other additives
which is then cut in a portioning process 520 to form individual
dissolvable-chewable tobacco tablets. Portioning process 520 can
include a process of rounding the edges of the dissolvable-chewable
tobacco tablets. For example, a pelletizer can be used to round the
edges. After portioning, the dissolvable-chewable tobacco tablets
can undergo a coating process 522 and a packaging process 524, each
of which is discussed above.
[0070] In addition to extrusion, there are other methods for mixing
and carefully controlling the temperature of a molten mixture used
to form dissolvable-chewable tobacco tablets provided herein.
Other Embodiments
[0071] It is to be understood that, while the invention has been
described herein in conjunction with a number of different aspects,
the foregoing description of the various aspects is intended to
illustrate and not limit the scope of the invention, which is
defined by the scope of the appended claims. Other aspects,
advantages, and modifications are within the scope of the following
claims.
[0072] Disclosed are methods and compositions that can be used for,
can be used in conjunction with, can be used in preparation for, or
are products of the disclosed methods and compositions. These and
other materials are disclosed herein, and it is understood that
combinations, subsets, interactions, groups, etc. of these methods
and compositions are disclosed. That is, while specific reference
to each various individual and collective combinations and
permutations of these compositions and methods may not be
explicitly disclosed, each is specifically contemplated and
described herein. For example, if a particular composition of
matter or a particular method is disclosed and discussed and a
number of compositions or methods are discussed, each and every
combination and permutation of the compositions and the methods are
specifically contemplated unless specifically indicated to the
contrary. Likewise, any subset or combination of these is also
specifically contemplated and disclosed.
* * * * *