U.S. patent application number 16/921128 was filed with the patent office on 2020-10-22 for tobacco compositions.
This patent application is currently assigned to U.S. Smokeless Tobacco Company LLC. The applicant listed for this patent is U.S. Smokeless Tobacco Company LLC. Invention is credited to Frank S. ATCHLEY, Armand J. DESMARAIS, Vernie A. DUE, Cherne W. JOHNSON, Tod J. MILLER, James M. ROSSMAN, James A. STRICKLAND, Scott A. WILLIAMS.
Application Number | 20200329755 16/921128 |
Document ID | / |
Family ID | 1000004939556 |
Filed Date | 2020-10-22 |
United States Patent
Application |
20200329755 |
Kind Code |
A1 |
STRICKLAND; James A. ; et
al. |
October 22, 2020 |
TOBACCO COMPOSITIONS
Abstract
The invention features tobacco compositions and methods of their
use and manufacture. Compositions of the invention may be based on
a variety of technologies. Technologies include films, tabs, shaped
parts, gels, consumable units, insoluble matrices, and hollow
shapes. In addition to tobacco, compositions may also contain
flavors, colors, and other additives as described herein.
Compositions may also be orally disintegrable. Exemplary
compositions and methods of their manufacture are described
herein.
Inventors: |
STRICKLAND; James A.;
(Richmond, VA) ; ATCHLEY; Frank S.; (Midlothian,
VA) ; ROSSMAN; James M.; (Richmond, VA) ;
DESMARAIS; Armand J.; (Richmond, VA) ; WILLIAMS;
Scott A.; (Richmond, VA) ; MILLER; Tod J.;
(Richmond, VA) ; JOHNSON; Cherne W.; (Richmond,
VA) ; DUE; Vernie A.; (Richmond, VA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
U.S. Smokeless Tobacco Company LLC |
Richmond |
VA |
US |
|
|
Assignee: |
U.S. Smokeless Tobacco Company
LLC
Richmond
VA
|
Family ID: |
1000004939556 |
Appl. No.: |
16/921128 |
Filed: |
July 6, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12345063 |
Dec 29, 2008 |
10765140 |
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16921128 |
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10982248 |
Nov 5, 2004 |
8469036 |
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12345063 |
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60603888 |
Aug 23, 2004 |
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60518352 |
Nov 7, 2003 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A24B 15/16 20130101;
A24B 13/00 20130101; A61K 36/81 20130101; A23L 27/79 20160801 |
International
Class: |
A24B 13/00 20060101
A24B013/00; A24B 15/16 20060101 A24B015/16; A61K 36/81 20060101
A61K036/81; A23L 27/00 20060101 A23L027/00 |
Claims
1-10. (canceled)
11. A shaped oral product comprising: tobacco; a plasticizer; a
water-soluble polymer; and water, the shaped oral product
configured to orally disintegrate in a time period of less than 60
minutes.
12. The shaped oral product of claim 11, wherein the water-soluble
polymer includes HPMC.
13. The shaped oral product of claim 11, wherein the water-soluble
polymer includes low-viscosity HPC.
14. The shaped oral product of claim 11, wherein the tobacco has a
particle size of less than or equal to 250 microns.
15. The shaped oral product of claim 14, wherein the particle size
is less than or equal to 80 microns.
16. The shaped oral product of claim 11, further comprising:
starch.
17. The shaped oral product of claim 16, wherein the starch
includes corn starch.
18. The shaped oral product of claim 11, further comprising:
soluble fibers.
19. The shaped oral product of claim 18, wherein the soluble fibers
include maltodextrin.
20. The shaped oral product of claim 11, further comprising:
microcrystalline cellulose.
21. The shaped oral product of claim 11, further comprising: a
sweetener.
22. The shaped oral product of claim 21, wherein the sweetener
includes sucralose.
23. The shaped oral product of claim 11, wherein the plasticizer
includes glycerin, propylene glycol, polyethylene glycol, sorbitol,
mannitol, triacetin, 1,3 butane diol, or any combination
thereof.
24. The shaped oral product of claim 23, wherein the tobacco is
present in an amount ranging from 25 weight percent to 80 weight
percent.
25. The shaped oral product of claim 11, wherein the tobacco is
present in an amount less than or equal to 30 weight percent.
26. The shaped oral product of claim 11, wherein the water-soluble
polymer is present in an amount ranging from 10 weight percent to
80 weight percent.
27. The shaped oral product of claim 26, wherein the amount ranges
from 20 weight percent to 50 weight percent.
28. The shaped oral product of claim 11, wherein the water is
present in an amount ranging from 5 weight percent to 10 weight
percent.
29. The shaped oral product of claim 11, wherein the time period
ranges from 1 minute to 10 minutes.
30. The shaped oral product of claim 11, wherein the shaped oral
product defines a shape of a tube, a toothpick, a stick, a twist,
or a solid rod.
31. The shaped oral product of claim 11, wherein the tobacco is a
tobacco extract.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Divisional application of and claims
benefit under 35 U.S.C. .sctn. 121 to U.S. application Ser. No.
10/982,248, filed Nov. 5, 2004, which claims benefit under 35
U.S.C. .sctn. 119(e) of U.S. Provisional Application No.
60/518,352, filed Nov. 7, 2003, and U.S. Provisional Application
No. 60/603,888, filed Aug. 23, 2004, each of which is hereby
incorporated by reference.
FIELD OF THE INVENTION
[0002] The invention relates to the field of tobacco products.
SUMMARY OF THE INVENTION
[0003] The invention features tobacco compositions and methods of
their use and manufacture. Compositions of the invention may be
based on a variety of technologies. Technologies include films,
tabs, shaped parts, gels, consumable units, insoluble matrices, and
hollow shapes. In addition to tobacco, compositions may also
contain flavors, colors, and other additives as described herein.
Compositions may also be orally disintegrable. Exemplary
compositions and methods of their manufacture are described
herein.
[0004] For example, any composition described herein may include a
flavor or flavor masking agent. Exemplary flavors include licorice,
kudzu, hydrangea, Japanese white bark magnolia leaf, chamomile,
fenugreek, clove, menthol, Japanese mint, aniseed, cinnamon, herb,
wintergreen, cherry, berry, apple, peach, Dramboui, bourbon,
scotch, whiskey, spearmint, peppermint, lavender, cardamon, apium
graveolens, cascarilla, nutmeg, sandalwood, bergamot, geranium,
honey essence, rose oil, vanilla, lemon oil, orange oil, cassia,
caraway, cognac, jasmin, ilangilang, sage, fennel, piment, ginger,
anise, coriander, coffee, or a mint oil from any species of the
genus Mentha.
[0005] Any composition of the invention may also include a
sweetener (such as sucrose, sucralose, acesulfame potassium,
aspartame, saccharine, cyclamates, lactose, sucrose, glucose,
fructose, sorbitol, and mannitol); a surfactant; a plasticizer
(such as glycerine, propylene glycol, polyethylene glycol,
sorbitol/mannitol, acetylated monoglycerides, triacetin, and 1,3
butane diol); a filler (such as starch, microcrystalline cellulose,
wood pulp, soluble fiber, calcium carbonate, dicalcium phosphate,
calcium sulfate, and a clay); a lubricant (such as stearic acid and
a stearate) or a wax (such as lecithin, glycerol monostearate, and
propylene glycol monostearate); a preservative (such as methyl
paraben and potassium sorbate); and/or a stabilizer (such as
ascorbic acid, monosterol citrate, BHT, and BHA).
[0006] Any composition described herein may further include a
coating, e.g., matte or glossy. The coating preferably includes a
color, flavor, sweetener, or flavor masking agent. The coating may
also include a different flavor, color, or rate of disintegration
from the format in the composition. The coating may also include
tobacco.
[0007] Any composition described herein may further include a
printed pattern, e.g., in a logo. A printed pattern may include a
color, tobacco, a flavor, sweetener, or flavor masking agent. The
surface of any composition described herein may also include a
pattern in relief.
[0008] Tobacco included in any composition may be a powder,
granules, shreds, or perceived to be soluble in the mouth.
[0009] Any composition described herein may further include flakes,
e.g., containing tobacco or a plurality of flavors or colors.
[0010] Any composition of the invention may be formed in a shape
suitable for application in the mouth. A composition of the
invention may further provide tobacco satisfaction, e.g., over a
period of 10 s to 30 minutes.
[0011] The invention also features a method for obtaining tobacco
satisfaction by placing at least a portion of any composition as
described herein in the mouth.
[0012] The invention also features methods for making compositions
as described herein. Any of these methods may further include
adding a coating to the composition, e.g., by spraying, brushing,
roll coating, doctor bar casting, slot coating, extrusion coating,
or hot melt deposition. Any of the methods may also include
printing a pattern on the composition, e.g., by offset,
flexographic, gravure, ink jet, laser, or screen printing. In
addition, the methods of making compositions may include adding a
flavor, color, flavor masking agent, or any other ingredient
described herein to the format or composition.
[0013] By "format" is meant an ingredient or compilation of
ingredients, as provided herein, in a composition, for example, a
carrier or agent.
[0014] By "tobacco" is meant any part, e.g., leaves, flowers,
roots, and stems, of any member of the genus Nicotiana. Exemplary
species of tobacco include N. rustica and N. tabacum (e.g., LA B21,
LN KY171, TI 1406, Basma, Galpao, Perique, Beinhart 1000-1, and
Petico). Other species include N. acaulis, N. acuminata, N.
acuminata var. multiflora, N. africana, N. alata, N. amplexicaulis,
N. arentsii, N. attenuata, N. benavidesii, N. benthamiana, N.
bigelovii, N. bonariensis, N. cavicola, N. clevelandii, N.
cordifolia, N. corymbosa, N. debneyi, N. excelsior, N. forgetiana,
N. fragrans, N. glauca, N. glutinosa, N. goodspeedii, N. gossei, N.
hybrid, N. ingulba, N. kawakamii, N. knightiana, N. langsdorffii,
N. linearis, N. longiflora, N. maritima, N. megalosiphon, N.
miersii, N. noctiflora, N. nudicaulis, N. obtusiblia, N.
occidentalis, N. occidentalis subsp. hesperis, N. otophora, N.
paniculata, N. pauciflora, N. petunioides, N. plumbaginiblia, N.
quadrivalvis, N. rainondii, N. repanda, N. rosulata, N. rosulata
subsp. ingulba, N. rotundifblia, N. setchellii, N. simulans, N.
solanifblia, N. spegazzinii, N. stocktonii, N. suaveolens, N.
svlvestris, N. thyrslora, N. tomentosa, N. tomentosiformis, N.
trigonophylla, N. umbratica, N. undulata, N. velutina, N.
wigandioides, and N..times.sanderae. The tobacco may be whole,
shredded, cut, cured, aged, fermented, or otherwise processed,
e.g., granulated or encapsulated. Tobacco may also be in the form
of finished products, including but not limited to any
non-combustible tobacco that is orally consumed, e.g., smokeless
tobacco. Such smokeless tobacco includes snuff (moist or dry),
chewing tobacco, loose tobacco, pouched tobacco, and the like, or
any form contained herein. The term also includes an extract of
tobacco including two or more tobacco organoleptic components.
[0015] By "tobacco satisfaction," in this case, is meant the
experience associated with tobacco organoleptic components and
added flavor components that are released in the mouth when using a
smokeless tobacco. An adult consumer who chooses to use a smokeless
tobacco product purchases a smokeless tobacco product typically
according to their individual preference, such a preference
includes, without limitation, flavor, cut of tobacco, form, ease of
use, and packaging.
[0016] By "organoleptic" is meant relating or contributing to the
integrated sensory perception by the consumer that includes, for
example, any combination of aroma, fragrance, flavor, taste, odor,
mouth feel, or the like.
[0017] By "non-combustible" is meant does not combust during
ordinary usage.
[0018] Compositions described herein are advantageous from the
perspective of size, ease of use, and controlled rate of
disintegration.
[0019] All percentages are by weight unless otherwise noted.
[0020] Other features and advantages will be apparent from the
following description and the claims.
DETAILED DESCRIPTION OF THE INVENTION
[0021] The invention features tobacco compositions that are
typically for tobacco satisfaction.
[0022] A. Tobacco
[0023] Tobacco useful in compositions described herein includes any
raw or processed form, e.g., a powder, granule, or shred.
Preferably, the tobacco is sized or made to disintegrate in the
mouth (e.g., dissolve), to give the perception of dissolvability
(e.g., the tobacco does not produce a tactile experience in the
mouth), or to be easily swallowed. Alternatively, the tobacco may
be sized or made to provide a tactile experience in the mouth.
Exemplary average sizes are in the range of 1 to 1000 .mu.m, e.g.,
about 800, 500, 250, 100, 80, 75, 50, 25, 20, 15, 10, 8, 6, 5, 3,
2, or m or less, preferably 80 .mu.m or less. The tobacco may also
be in the form of a slurry or a flowable gel. A flowable gel is a
mixture of a format dissolved in water and mixed with tobacco and
then mixed with a miscible solvent that prevents the complete
dissolution of the format. Such a mixture causes the format to
swell forming a viscous paste that is pseudoplastic and is easily
dispensed from a container (e.g., a tube) with slight pressure. An
exemplary tobacco is smokeless tobacco. Additional tobaccos are
described in U.S. Publication Nos. 2003/0094182 and 2003/0070687,
U.S. Ser. No. 60/603,887, and U.S. Ser. No. ______ titled
"Nicotiana Compositions," filed Nov. 5, 2004; the disclosures of
which are hereby incorporated by reference. The tobacco employed in
the composition may also be prepared according to the methods of
U.S. Publication No. 2004/0112394; the disclosure of which is
hereby incorporated by reference. Other suitable tobacco is known
in the art.
[0024] Tobacco may be distributed randomly or evenly throughout a
composition or concentrated in various regions thereof, e.g., in
the center or on the surface.
[0025] Depending on the desired characteristics and the end use of
the composition, the typical final tobacco concentration ranges
from 1 percent to 99 percent by weight of the final composition,
for example, at most 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60,
65, 70, 75, 80, 85, or 90%. In preferred embodiments, the
composition includes around 25% tobacco.
[0026] B. Compositions
[0027] In general, compositions of the invention are intended for
oral use or consumption. A composition containing tobacco may be
manufactured using any suitable orally compatible format. The
tobacco may be mixed directly with the format or otherwise
supported by the format. For example, a composition may contain
tobacco, e.g., as dried particles, shreds, granules, a powder, or a
slurry, deposited on, mixed in, surrounded by, or otherwise
combined with a format. Tobacco in compositions may or may not be,
or be perceived to be, soluble. In one embodiment, the compositions
are spitless tobacco compositions. Compositions may also include a
mixture of forms or types of tobacco. Compositions may be foamed or
dense. Foamed compositions may be rigid or flexible and may be
based on water soluble, water insoluble, or thermoplastic formats.
Exemplary compositions are described herein. In one embodiment, a
composition of the invention is non-combustible.
[0028] Formats suitable for use in the compositions described
herein include orally compatible polymers, such as cellulosics
(e.g., carboxymethyl cellulose (CMC), hydroxypropyl cellulose
(HPC), hydroxyethyl cellulose (HEC), hydroxypropyl methyl cellulose
(HPMC), and methyl cellulose (MC)), natural polymers (e.g.,
starches and modified starches, konjac, collagen, inulin, soy
protein, whey protein, casein, and wheat gluten), seaweed-derived
polymers (e.g., carrageenan (kappa, iota, and lambda), alginates,
and propylene glycol alginate), microbial-derived polymers (e.g.,
xanthan, dextran, pullulan, curdlan, and gellan), extracts (e.g.,
locust bean gum, guar gum, tara gum, gum tragacanth, pectin (lo
methoxy and amidated), agar, zein, karaya, gelatin, psyllium seed,
chitin, and chitosan), exudates (e.g., gum acacia (arabic) and
shellac), synthetic polymers (e.g., polyvinyl pyrrolidone,
polyethylene oxide, and polyvinyl alcohol). Other useful formats
are known in the art, for example, see Krochta et al. Food
Technology, 1997, 51:61-74, Glicksman Food Hydrocolloids CRC 1982,
Krochta Edible Coatings and Films to Improve Food Quality Technomic
1994, Industrial Gums Academic 1993, Nussinovitch Water-Soluble
Polymer Applications in Foods Blackwell Science 2003. Depending on
the desired characteristics, a composition may also include fillers
(e.g., starch, microcrystalline cellulose, wood pulp (e.g.,
Solkafloc from International Fibers, Inc.), soluble fiber (e.g.,
Fibersol from Matsushita), calcium carbonate, dicalcium phosphate,
calcium sulfate, and clays), lubricants (e.g., lecithin, stearic
acid, stearates (e.g., Mg or K), and waxes (e.g., glycerol
monostearate, propylene glycol monostearate, and acetylated
monoglycerides)), plasticizers (e.g., glycerine, propylene glycol,
polyethylene glycol, sorbitol, mannitol, triacetin, and 1,3 butane
diol), stabilizers (e.g., ascorbic acid and monosterol citrate,
BHT, or BHA), or other compounds (e.g., vegetable oils,
surfactants, and preservatives). Some compounds function as both
plasticizers and lubricants.
[0029] Compositions of the invention may include flavor extracts
(e.g., licorice, kudzu, hydrangea, Japanese white bark magnolia
leaf, chamomile, fenugreek, clove, menthol, Japanese mint, aniseed,
cinnamon, herb, wintergreen, cherry, berry, peach, apple, Dramboui,
bourbon, scotch, whiskey, spearmint, peppermint, lavender,
cardamon, apium graveolens, cascarilla, nutmeg, sandalwood,
bergamot, geranium, honey essence, rose oil, vanilla, lemon oil,
orange oil, cassia, caraway, cognac, jasmin, ilangilang, sage,
fennel, piment, ginger, anise, coriander, coffee, or a mint oil
from any species of the genus Mentha), flavor masking agents,
bitterness receptor site blockers, receptor site enhancers,
sweeteners (e.g., sucralose, acesulfame potassium (Ace-K),
aspartame, saccharine, cyclamates, lactose, sucrose, glucose,
fructose, sorbitol, and mannitol), and other desirable additives
such as chlorophyll, minerals, botanicals, or breath freshening
agents.
[0030] Flavors may also be provided by plant matter, e.g., mint
leaves, which are typically 10% flavor oils and 90% insoluble
fiber. Exemplary plants further include licorice, kudzu, hydrangea,
Japanese white bark magnolia, chamomile, fenugreek, clove, Japanese
mint, cinnamon, herb, cherry, berry, peach, apple, lavender,
cardamon, apium graveolens, cascarilla, nutmeg, sandalwood,
bergamot, geranium, rose, vanilla, lemon, orange, cassia, caraway,
jasmin, ilangilang, sage, fennel, piment, ginger, anise, coriander,
coffee, or any species of the genus Mentha.
[0031] Flavor may be provided to a composition as described herein
by flavor extracts, plant matter, or a combination thereof. In
addition to natural flavor extracts, flavor may also be provided by
imitation, synthetic, or artificial flavor ingredients and blends
containing such ingredients. Flavors may be added as a powder, an
oil, or in encapsulated form.
[0032] In certain embodiments, the composition disintegrates in the
mouth. Disintegration rates of compositions may vary from 60
minutes to less than 1 minute. Fast release compositions typically
disintegrate in under 2 minutes and most preferably, in 1 minute or
less, e.g., less than 60 s, 50 s, 45 s, 40 s, 35 s, 30 s, 25 s, 20
s, 15 s, 10 s, 5 s, 4 s, 3 s, 2 s, or s. The disintegration may
occur by any mechanism, for example, dissolution, melting,
mechanical disruption (e.g., from chewing), enzymatic or other
chemical degradation, or disruption of the interaction between the
format and tobacco. The format or tobacco itself may similarly
disintegrate. The amount of time required for a composition to
disintegrate may be controlled by varying the thickness of the
composition and is dependent upon the type of format, other
additives, and the pattern of usage. When placed in the mouth, the
composition may temporarily adhere to a part of the oral mucosa. In
addition, the length of time of the tobacco satisfaction may vary.
This length of time may be affected by, e.g., by the rate of
disintegration of a composition, the rate of extraction of
organoleptic components from a composition, and the residence time
of the composition in the mouth. The tobacco satisfaction may be
provided over a period of at least 10 s, 30 s, 45 s, 1 min 2 min 3
min 5 min 10, min 15 min, 30 min, or 1 h, preferably from 10 s to
10 minutes and more preferably from 30 s to 5 minutes.
[0033] In other embodiments, the compositions do not disintegrate
over the residence period in the mouth. In such compositions,
introduction of tobacco organoleptic components into the mouth may
occur by dissolution, leaching, extraction, or mechanical
disruption caused by chewing.
[0034] Individual compositions may be sized to fit entirely in the
mouth, or they may be sized to fit only partially in the mouth.
Preferred cross sections of the compositions include, but are not
limited to, square, circular, rectangular, elliptical, oval, and
the like. Preferred dimensions may vary depending upon the serving
size and ingredients. Typically, the largest dimension of a single
serving is 5 cm or smaller. Alternatively, tobacco products may be
made in a larger form, from which individual servings may be cut or
otherwise separated, e.g., by chewing, biting, or oral
disintegration. For example, a strip, or other long piece, may be
placed in a container, and the consumer may remove a desired
serving size. A larger composition (or orally sized piece attached
to a handle) may also be partially inserted in the mouth, similar
to a toothpick or cigarette, and the consumer may suck or chew on
it. In one embodiment, the larger piece is orally disintegrable and
may be completely consumed over a period of time.
[0035] C. Technologies
[0036] Films.
[0037] Compositions of the invention may be formed as films that
may be orally disintegrable. Such films may contain a single layer
or multiple layers. A single layer film will contain tobacco, a
format, and other ingredients, e.g., in a homogeneous mixture.
Multilayer films may include several tobacco containing layers,
e.g., with the same or different kind or size of tobacco, e.g.,
tobacco perceived to be soluble. Multiple layers may be laminated
together. In addition, multilayer films may contain tobacco in one
or more layers and other layers that contain additional
ingredients, as described herein. For example, individual layers
may be added for flavor, sweetness, color, rate of disintegration,
or stability (e.g., during handling or during consumption). Tobacco
may also be placed between two or more layers in a sandwich
arrangement. One or more of the layers in the sandwich may also
include tobacco. In films having multiple layers, the layers may
disintegrate at the same or different rates, or a layer may not
disintegrate orally. When rates of disintegration differ, the
composition may provide tobacco at differing times based on the
layers disintegrating. Single layer films or individual layers in
multilayer films may also be foamed or aerated to provide desirable
physical properties or desirable dissolution or disintegration
rates.
[0038] Films may be sized to fit in the mouth as individual
servings. Alternatively, larger films may be fabricated from which
individual servings may be separated. For example, a film may be
wrapped, or otherwise shaped, to form a hollow tube or straw, which
in turn may be filled with additional material. In addition, a
film, e.g., containing a high percentage of tobacco in the range of
1% to 99% based on dry weight, may be fabricated and then used in
preparation of flakes or a powder for addition to other
compositions, as described herein. The preferred thickness of a
film is typically less than 1 mm, e.g., less than 500, 200, 100,
50, 40, 30, 20, 10, 5, 4, 3, 2, or 1 .mu.m; preferably 5 to 125
.mu.m.
[0039] Various methods known in the art can be used to manufacture
films. The technique employed may depend on the format employed in
the film. Exemplary methods include solution casting or extrusion,
melt extrusion, drum drying, and calendaring. Once formed, a film
may be modified, e.g., by printing or otherwise coating or
decorating the surface of the film. Flavors, colors, or tobacco may
be added to the surface of a film by a printing, coating, or
decorative process. All printing processes known in the art, e.g.,
offset, flexographic, gravure, ink jet, laser, screen printing, and
other typical methods, may be used. Coatings or decorative patterns
may be applied to the surface of the film using processes known in
the art, e.g., spraying, brushing, roll coating, doctor bar
casting, slot coating, extrusion coating, hot melt deposition,
depositing particles or flakes, and other typical methods. The film
to be printed, coated, or decorated may or may not contain tobacco.
One function of the printing, coating, or decorative pattern is to
provide additional amounts of color, flavor, or tobacco to the
film. Another function is to improve the dimensional stability and
appearance of the film. Once the printed, coated, or decorated film
has been prepared, an additional layer of film may be applied to
cover, protect and seal the printed, coated, or decorated
surface.
Film Examples
[0040] The following table shows exemplary ingredients for
fabricating films of the invention.
TABLE-US-00001 TABLE A1 Exemplary Preferred Example A (%) (%) (%)
Water soluble polymer 10-70 20-45 30 Tobacco 1-90 20-40 25 Flavor
1-40 5-15 10 Sweetener 0.2-6 2-5 3 Fiber (Soluble or insoluble)
2-40 5-20 9 Plasticizer 1-40 5-15 10 Surfactants 0.05-5 0.1-1 0.5
Starch/Maltodextrin 1-40 10-20 10.5 Lubricant 0.5-10 1-3 2
Example B. Tobacco Film
[0041] A mixture of 50 grams of K-3 (60%), K-100 (35%) and K4M (5%)
grades of hydroxypropylmethyl cellulose (HPMC) from Dow Chemical
are added to a beaker containing 450 grams of well agitated,
deionized water which has been heated to 180.degree. F. While
mixing, 40 grams of finely ground tobacco is added to the HPMC
solution along with 15 grams of microcrystalline cellulose (FMC),
17 grams of starch (B-700 from Grain Processing Corp.), 16 grams of
glycerine, 0.8 grams of polysorbate 80 (Unichema), and 4 grams of
propylene glycol monostearate (PGMS from Danisco). Ten grams of
cinnamon flavor and 2 grams of sucralose (artificial sweetener) are
added to the solution when the temperature has dropped below
100.degree. F. Two grams of sodium carbonate is added to adjust pH
to approximately 7.5. Once all ingredients have been added and have
been uniformly dispersed, the mixture is place in a water bath and,
with continued mixing for 30 minutes, is reduced in temperature to
65.degree. F. Additional water is added as required to obtain a
Brookfield viscosity of 5,000 centipoise at a temperature of
65.degree. F.
[0042] A portion of this tobacco containing solution described
above is then spread on a glass plate using a draw down blade with
a fixed gap of 15 mils (0.015 inches). The glass plate is placed in
an air circulating laboratory oven preset at a temperature of
170.degree. F. After 30 minutes, the glass plate is removed from
the oven, cooled to room temperature, and the dry film with a
thickness of 2.5 mils (0.0025 inches) is removed from the glass
plate. The film may then be cut into smaller pieces suitable for
placing in the mouth. A 1.0 inch by 1.25 inch section of the film
will typically disintegrate in the mouth in less than one minute,
thereby releasing the flavor, sweetener, and tobacco. The tobacco
content of this film on a dry weight basis is 25%.
Example C. Opaque, Flavored Film
[0043] Using the same procedure as Example B, a solution is
prepared without the addition of tobacco. While the solution is
still hot, 32 grams of a titanium dioxide dispersion (50% titanium
dioxide in water) supplied by Sensient Colors and 0.01 grams of
FD&C Red No. 40 lake (Sensient Colors) are added with
agitation. The solution is cooled to 65.degree. F. and is spread on
a glass plate, dried, and removed from the glass plate as described
in Example B. An opaque, light red film of good strength and a dry
film thickness of 1.5 mils (0.015 inches) is produced.
Example D. Two Layer Film
[0044] A portion of the solution from Example B is spread on a
glass plate using a draw down blade with a fixed gap of 15 mils
(0.015 inches). The glass plate is placed in a laboratory oven and
the film is dried as in Example B. The glass plate is removed from
the oven and cooled to room temperature, but the film is not
removed from the glass plate.
[0045] A portion of the solution from Example C is spread over the
dry film of Example B using a draw down blade with a fixed gap of 5
mils (0.005 inches). The glass plate is placed in the laboratory
oven at 170.degree. F. for 10 minutes. The dry film with a
thickness of 3 mils (0.003 inches) is removed from the glass plate.
The film is distinctly two sided with a layer of brown, tobacco
containing film on one side and a red, flavored film on the
opposite side. A 1.0 inch by 1.25 inch section of the film will
typically disintegrate in the mouth in less than one minute.
Example E. Three Layer Film
[0046] A portion of the solution from Example C is spread on a
glass plate using a draw down blade with a fixed gap of 5 mils and
is dried in the laboratory oven as before. A portion of the
solution from Example B is spread over the dried film of Example C
using a draw down blade with a fixed gap of 15 mils and is dried in
the laboratory oven as before. A portion of the solution from
Example C is spread on a glass plate using a draw down blade with a
fixed gap of 5 mils and is dried in the laboratory oven as before.
The resulting film is 3 mils (0.003 inches) in thickness and is
comprised of three layers with a layer of opaque, red, flavored
film on either side and a center layer of tobacco containing film.
A 1.0 inch by 1.25 inch section of the film will typically
disintegrate in the mouth in less than one minute.
Example F. Foamed Film
[0047] To a 100 gram portion of tobacco containing solution from
Example B is added with vigorous mixing, 0.5 grams of sodium lauryl
sulfate (a surface active agent). This solution is then mixed on a
high shear mixer such as a Siverson Laboratory Homogenizer, Model
L4RT-W, to create a uniform bubble structure. This highly aerated
solution is then spread on a glass plate using a draw down blade
with a fixed gap of 4 mils (0.040 inches) and is dried in a
laboratory oven. The dry, foamed film has a thickness of 4 mils
(0.004 inches) when it is removed from the glass plate. The weight
of a section of this foamed film of 1.0 inch by 1.25 inch by 4 mils
(0.004 inches) in thickness is 35% lower than an identical section
of unfoamed film as prepared in Example B. The dissolution rate of
the foamed film in the mouth is typically faster when compared to
the identical unfoamed film as prepared in Example B.
Example G. Flakes
[0048] A solution is prepared in a beaker by adding 40 grams of
spray dried Gum Arabic (TIC Gums, Inc.) and 0.4 grams of propylene
glycol monostearate (PGMS) to 60 grams deionized water while mixing
vigorously for 30 minutes. To 10 grams of this solution, 0.01 grams
of FD&C Red No. 40 lake is added with high agitation to ensure
uniform dispersion of the color. The solution is covered and set
aside for 24 hours to permit all entrapped air to dissipate. A
portion of this solution is then spread on a glass plate using a
draw down blade with a fixed gap of 5 mils (0.005 inches). The
glass plate is placed in a laboratory oven preset at 170.degree. F.
for 20 minutes until the film is thoroughly dried. When the film is
removed from the glass plate, it breaks into many small pieces of
high gloss, colorful, red flakes. This process is repeated with
other FD&C lakes to produce flakes of many different colors.
Flavors and artificial sweeteners can also be added to the
flakes.
Example H. Tobacco Flakes
[0049] To 10 grams of the solution prepared in Example G is added 4
grams of finely ground tobacco powder. Films are prepared on glass
plates and are dried, cooled, and removed in the same manner as in
Example G. The resulting flakes are composed of 50% tobacco and 50%
Gum Arabic and are a deep brown color. Flavors, if desired, can be
added to the flakes. Materials such as sodium carbonate can also be
added to the flakes to adjust pH.
Example I. Tobacco Film with Flakes
[0050] A film is prepared as in Example B. While the film is still
wet on the glass plate, a measured quantity of flakes are prepared
and are spread uniformly over the wet film. The glass plate is then
dried in a laboratory oven; the film is cooled to room temperature
and then removed from the glass plate. Typically, the dried film of
Example B has a dry weight of 1 gram (containing 25% or 0.25 grams
of tobacco). If this film is divided into 20 equal sections of film
(1.0 inch by 1.25 inches by 2 mils), each section will weigh 50
milligrams (containing 25% or 12.5 milligrams of tobacco). If one
gram of tobacco flakes (which are 50% by weight of tobacco) are
spread uniformly over the film, the full piece of film will have a
dry weight of 2 grams (containing a total of 0.75 grams of
tobacco). When divided into 20 equal sections, each section will
weigh 100 milligrams and will contain 37.5 milligrams of tobacco.
The section of film cut into a 1.0 inch by 1.25 inch size will
typically disintegrate in the mouth in less than one minute.
Example J. Tobacco Film with Decorative Flakes
[0051] The procedure outlined in Example I can be repeated using
decorative flakes (e.g., colored flakes which do not contain any
tobacco) or with blends of colored flakes and tobacco containing
flakes. The resulting films have a colorful appearance.
Example K. Flavored Tobacco Film
TABLE-US-00002 [0052] TABLE K1 HPMC 36.56% Starch 12.18% Tobacco
24.37% Na.sub.2CO.sub.3 1.46% Plasticizer 13.15% Flavors 6.82%
Sweetener 0.49% Surfactant 0.97% Water 4.00%
[0053] The following ingredients were weighed and combined in a
container of suitable volume:
TABLE-US-00003 MIX1 HM3PA2910(Wolff Cellulosics) 30.98 g
HM100PA2208(Wolff Cellulosics) 15.51 g HM4000PA2910(Wolff
Cellulosics) 2.60 g B700(Grain Processing Corporation) 16.36 g
Tobacco Powder (average particle size <80 .mu.m) 32.72 g
[0054] The resultant mixture was mixed until homogeneous. In a
separate container were weighed the following ingredients:
TABLE-US-00004 MIX2 Na.sub.2CO.sub.3 1.96 g Propylene Glycol
Monostearate 0.65 g Sodium Lauryl Sulfate 0.65 g
[0055] In a third container were weighed the following
ingredients:
TABLE-US-00005 MIX3 Glycerin 5.89 g Propylene Glycol 5.22 g
Polyethylene Glycol 400 6.54 g Cinnamon Flavor 6.54 g Tobacco
Flavor Modifier (Hagelin) 2.62 g Sueralose Solution 25% (Tate &
Lyle) 2.62 g
[0056] A total of 619.14 g of boiling water was weighed into a
stainless steel container. The water was stirred vigorously with an
Arrow Model 1750 high shear mixer. To the water was added MIX2.
Stirring was continued for 30 seconds, at which point MIX1 was
added. Vigorous stirring was continued for 4 minutes. To the
resultant solution was added MIX3. Vigorous stirring was continued
for 1 minute. The resultant solution was transferred to a Silverson
SS1 vessel, which had been adapted for mixing under vacuum. The
vessel was attached to a Silverson L4RTU homogenizer motor unit.
The solution was homogenized under vacuum (20-25 inches of Hg) for
2 minutes at 7500 RPM, after which an ice bath was placed around
the homogenizer vessel. Homogenization continued under vacuum
(20-25 inches of Hg) for 8 minutes at 10,000 RPM. After
homogenization was complete, a portion of the solution was
transferred to a 500-mL Nalgene bottle for storage.
[0057] A portion of the resultant gel solution was poured onto a
glass plate that had previously been covered with an appropriately
sized sheet of Mylar. The gel solution was drawn across the glass
plate with a draw-down knife with a fixed gap of 15 mils. The glass
plate was placed in a side-swept forced air oven (VWR model
1330FM), for 30 minutes, which had been set at 75.degree. C. The
resultant film, dried to approximately 4% moisture, was removed
from the Mylar sheet and cut into appropriately sized units. A 1.0
inch by 1.25 inch unit of film disintegrated in the mouth in less
than 30 seconds.
[0058] Relatively slower disintegrating films (e.g., films
disintegrating in the mouth in greater than 30 seconds) were
produced from the same solutions by casting the solution across the
glass plate with a draw-down knife with a fixed gap of 30 mils. The
films were dried in the same manner as above for 40 minutes. The
films produced typically disintegrated in the mouth in less than 1
minute.
[0059] Super-fast disintegrating films (e.g., films disintegrating
in the mouth in less than 15 seconds) were produced from the same
solutions by foaming the solution prior to casting on the glass
plate. Foaming was accomplished by subjecting 100 g of each
solution to high shear mixing (with an Arrow Model 1750 high shear
mixer) for approximately 3 minutes, after which the foamed solution
was immediately cast on the glass plate with a draw-down knife with
a fixed gap of 30 mils. The films produced typically disintegrated
in the mouth in less than 15 seconds.
Example L. Flavored Tobacco Film
TABLE-US-00006 [0060] TABLE L1 HPMC 36.56% Starch 12.18% Tobacco
24.37% Na.sub.2CO.sub.3 1.46% Plasticizer 10.71% Flavors 9.26%
Sweetener 0.49% Surfactant 0.97% Water 4.00%
[0061] The following ingredients were weighed and combined in a
container of suitable volume:
TABLE-US-00007 MIX1 HM3PA2910(Wolff Cellulosics) 30.98 g
HM100PA2208(Wolff Cellulosics) 15.51 g HM4000PA2910(Wolff
Cellulosics) 2.60 g B700(Grain Processing Corporation) 16.36 g
Tobacco Powder (avg. particle size <80 .mu.m) 32.72 g
[0062] The resultant mixture was mixed until homogeneous. In a
separate container were weighed the following ingredients:
TABLE-US-00008 MIX2 Na.sub.2CO.sub.3 1.96 g Propylene Glycol
Monostearate 0.65 g Sodium Lauryl Sulfate 0.65 g
[0063] In a third container were weighed the following
ingredients:
TABLE-US-00009 MIX3 Glycerin 4.58 g Propylene Glycol 5.22 g
Polyethylene Glycol 400 4.58 g Mint Flavor 9.81 g Tobacco Flavor
Modifier (Hagelin) 2.62 g Sucralose Solution 25% (Tate & Lyle)
2.62 g
[0064] A total of 619.14 g of boiling water was weighed into a
stainless steel container. The water was stirred vigorously with an
Arrow Model 1750 high shear mixer. To the water was added MIX2.
Stirring was continued for 30 seconds, at which point MIX1 was
added. Vigorous stirring was continued for 4 minutes. To the
resultant solution was added MIX3. Vigorous stirring was continued
for 1 minute. The resultant solution was transferred to a Silverson
SS1 vessel, which had been adapted for mixing under vacuum. The
vessel was attached to a Silverson L4RTU homogenizer motor unit.
The solution was homogenized under vacuum (20-25 inches of Hg) for
2 minutes at 7500 RPM, after which an ice bath was placed around
the homogenizer vessel. Homogenization continued under vacuum
(20-25 inches of Hg) for 8 minutes at 10000 RPM. After
homogenization was complete, a portion of the solution was
transferred to a 500-mL Nalgene bottle for storage.
[0065] A portion of the resultant gel solution was poured onto a
glass plate that had previously been covered with an appropriately
sized sheet of Mylar. The gel solution was drawn across the glass
plate with a draw-down knife with a fixed gap of 15 mils. The glass
plate was placed in a side-swept forced air oven (VWR model
1330FM), for 30 minutes, which had been set at 75.degree. C. The
resultant film, dried to approximately 4% moisture, was removed
from the Mylar sheet and cut into appropriately sized units. A 1.0
inch by 1.25 inch unit of film typically disintegrated in the mouth
in 15-30 seconds.
[0066] Alternatively, the film includes wintergreen, spearmint, or
apple flavor.
[0067] Relatively slower disintegrating films (e.g., films
disintegrating in the mouth in greater than 30 seconds) and
super-fast disintegrating films (e.g., films disintegrating in the
mouth in less than 15 seconds) were produced from the same
solutions as described in Example K.
Example M. Peach Flavored Tobacco Film
TABLE-US-00010 [0068] TABLE M1 HPMC 29.12% Starch 9.71% Tobacco
19.41% Na.sub.2CO.sub.3 1.16% Plasticizer 2.33% Peach Puree 29.66%
Flavors 3.43% Sweetener 0.39% Surfactant 0.77% Water 4.00%
[0069] The following ingredients were weighed and combined in a
container of suitable volume:
TABLE-US-00011 MIX1 HM3PA2910(Wolff Cellulosics) 30.98 g
HM100PA2208(Wolff Cellulosics) 15.51 g HM4000PA2910(Wolff
Cellulosics) 2.60 g B700(Grain Processing Corporation) 16.36 g
Tobacco Powder (average particle size <80 .mu.m) 32.72 g
[0070] The resultant mixture was mixed until homogeneous. In a
separate container were weighed the following ingredients:
TABLE-US-00012 MIX2 Na.sub.2CO.sub.3 1.96 g Propylene Glycol
Monostearate 0.65 g Sodium Lauryl Sulfate 0.65 g
[0071] In a third container were weighed the following
ingredients:
TABLE-US-00013 MIX3 Glycerin 1.31 g Propylene Glycol 1.31 g
Polyethylene Glycol 400 1.31 g Peach Puree 100.0 g Peach Flavor
3.27 g Tobacco Flavor Modifier (Hagelin) 2.62 g Sucralose Solution
25% (Tate & Lyle) 2.62 g
[0072] A total of 619.14 g of boiling water was weighed into a
stainless steel container. The water was stirred vigorously with an
Arrow Model 1750 high shear mixer. To the water was added MIX2.
Stirring was continued for 30 seconds, at which point MIX1 was
added. Vigorous stirring was continued for 4 minutes. To the
resultant solution was added MIX3. Vigorous stirring was continued
for 1 minute. The resultant solution was transferred to a Silverson
SS1 vessel, which had been adapted for mixing under vacuum. The
vessel was attached to a Silverson L4RTU homogenizer motor unit.
The solution was homogenized under vacuum (20-25 inches of Hg) for
2 minutes at 7500 RPM, after which an ice bath was placed around
the homogenizer vessel. Homogenization continued under vacuum
(20-25 inches of Hg) for 8 minutes at 10000 RPM. After
homogenization was complete, a portion of the solution was
transferred to a 500-mL Nalgene bottle for storage.
[0073] A portion of the resultant gel solution was poured onto a
glass plate which had previously been covered with an appropriately
sized sheet of Mylar. The gel solution was drawn across the glass
plate with a draw-down knife with a fixed gap of 15 mils. The glass
plate was placed in a side-swept forced air oven (VWR model
1330FM), for 30 minutes, which had been set at 75.degree. C. The
resultant film, dried to approximately 4% moisture, was removed
from the Mylar sheet, and cut into appropriately sized units. A 1.0
inch by 1.25 inch unit of film typically disintegrated in the mouth
in 15-30 seconds.
[0074] Relatively slower disintegrating films (e.g., films
disintegrating in the mouth in greater than 30 seconds) and
super-fast disintegrating films (e.g., films disintegrating in the
mouth in less than 15 seconds) were produced from the same
solutions as described in Example K.
Example N. Flavored Tobacco Film for Sticks/Wraps/Pouches/Vacuum
Forming
TABLE-US-00014 [0075] TABLE N1 HPMC 41.31% Starch 13.76% Tobacco
9.75% Na.sub.2CO.sub.3 1.46% Plasticizer 18.99% Flavors 9.27%
Sweetener 0.49% Surfactant 0.98% Water 4.00%
[0076] The following ingredients were weighed and combined in a
container of suitable volume:
TABLE-US-00015 MIX1 HM3PA2910(Wolff Cellulosics) 38.48 g
HM100PA2208(Wolff Cellulosics) 19.27 g HM4000PA2910(Wolff
Cellulosics) 3.24 g B700(Grain Processing Corporation) 20.32 g
Tobacco Powder (avg. particle size <80 .mu.m) 14.39 g
[0077] The resultant mixture was mixed until homogeneous. In a
separate container were weighed the following ingredients:
TABLE-US-00016 MIX2 Na.sub.2CO.sub.3 2.16 g Propylene Glycol
Monostearate 0.72 g Sodium Lauryl Sulfate 0.72 g
[0078] In a third container were weighed the following
ingredients:
TABLE-US-00017 MIX3 Glycerin 7.19 g Propylene Glycol 7.19 g
Polyethylene Glycol 400 7.19 g Triacetin 6.47 g Cinnamon Flavor
10.80 g Tobacco Flavor Modifier (Hagelin) 2.88 g Sucralose Solution
25% (Tate & Lyle) 2.88 g
[0079] A total of 606.10 g of boiling water was weighed into a
stainless steel container. The water was stirred vigorously with an
Arrow Model 1750 high shear mixer. To the water was added MIX2.
Stirring was continued for 30 seconds, at which point MIX1 was
added. Vigorous stirring was continued for 4 minutes. To the
resultant solution was added MIX3. Vigorous stirring was continued
for 1 minute. The resultant solution was transferred to a Silverson
SS1 vessel, which had been adapted for mixing under vacuum. The
vessel was attached to a Silverson L4RTU homogenizer motor unit.
The solution was homogenized under vacuum (20-25 inches of Hg) for
2 minutes at 7500 RPM, after which an ice bath was placed around
the homogenizer vessel. Homogenization continued under vacuum
(20-25 inches of Hg) for 8 minutes at 10000 RPM. After
homogenization was complete, a portion of the solution was
transferred to a 500-mL Nalgene bottle for storage.
[0080] A portion of the resultant gel solution was poured onto a
glass plate which had previously been covered with an appropriately
sized sheet of Mylar. The gel solution was drawn across the glass
plate with a draw-down knife with a fixed gap of 20 mils. The glass
plate was placed in a side-swept forced air oven (VWR model
1330FM), for 35 minutes, which had been set at 75.degree. C. The
resultant film, dried to approximately 4% moisture, was removed
from the Mylar sheet, and was stored in a plastic bag for future
use.
[0081] Alternatively flavored tobacco films, e.g., apple flavored,
were also produced following the preceding formulation and
procedure.
Example O. Flavored/Colored Film for Sticks/Wraps/Pouches
TABLE-US-00018 [0082] TABLE O1 HPMC 41.31% Starch 13.76% Fibersol-2
9.75% Na.sub.2CO.sub.3 1.46% Plasticizer 18.99% Flavors 9.26%
Sweetener 0.49% Surfactant 0.79% Color 0.20% Water 4.00%
[0083] The following ingredients were weighed and combined in a
container of suitable volume:
TABLE-US-00019 MIX1 HM3PA2910(Wolff Cellulosics) 38.48 g
HM100PA2208(Wolff Cellulosics) 19.27 g HM4000PA2910(Wolff
Cellulosics) 3.24 g B700(Grain Processing Corporation) 20.32 g
Fibersol-2(Matsutani) 14.39 g FD&C Red 40 Alum Lake 35-42%
(Sensient Colors) 0.29 g
[0084] The resultant mixture was mixed until homogeneous. In a
separate container were weighed the following ingredients:
TABLE-US-00020 MIX2 Na.sub.2CO.sub.3 2.16 g Propylene Glycol
Monostearate 0.58 g Sodium Lauryl Sulfate 0.58 g
[0085] In a third container were weighed the following
ingredients:
TABLE-US-00021 MIX3 Glycerin 7.19 g Propylene Glycol 7.19 g
Polyethylene Glycol 400 7.19 g Triacetin 6.47 g Cinnamon Flavor
10.79 g Tobacco Flavor Modifier (Hagelin) 2.88 g Sucralose Solution
25% (Tate & Lyle) 2.88 g
[0086] A total of 606.10 g of boiling water was weighed into a
stainless steel container. The water was stirred vigorously with an
Arrow Model 1750 high shear mixer. To the water was added MIX2.
Stirring was continued for 30 seconds, at which point was added
MIX. Vigorous stirring was continued for 4 minutes. To the
resultant solution was added MIX3. Vigorous stirring was continued
for 1 minute. The resultant solution was transferred to a Silverson
SS1 vessel, which had been adapted for mixing under vacuum. The
vessel was attached to a Silverson L4RTU homogenizer motor unit.
The solution was homogenized under vacuum (20-25 inches) for 2
minutes at 7500 RPM, after which an ice bath was placed around the
homogenizer vessel. Homogenization continued under vacuum (20-25
inches) for 8 minutes at 10000 RPM. After homogenization was
complete, a portion of the solution was transferred to a 500-mL
Nalgene bottle for storage.
[0087] A portion of the resultant gel solution was poured onto a
glass plate that had previously been covered with an appropriately
sized sheet of Mylar. The gel solution was drawn across the glass
plate with a draw-down knife with a fixed gap of 20 mils. The glass
plate was placed in a side-swept forced air oven (VWR model
1330FM), for 35 minutes, which had been set at 75.degree. C.
Additional films were cast at 40 mils, and dried for 1 hour. The
resultant films dried to approximately 4% moisture, were removed
from the Mylar sheet, and were stored in a plastic bag for future
use.
[0088] Alternatively flavors include mint flavor, wintergreen
flavor, or spearmint flavor. Alternative colors include FD&C
Blue Alum Lake 35-42%, FD&C Emerald Green Lake Blend, and
FD&C Blue Alum Lake+FD&C Emerald Green Lake Blend.
Example P. Peach Flavored Film for Sticks/Wraps/Pouches
TABLE-US-00022 [0089] Table P1 HPMC 31.73% Starch 10.57% Tobacco
7.49% Na.sub.2CO.sub.3 1.12% Plasticizer 14.59% Peach Puree 26.01%
Flavors 3.37% Sweetener 0.37% Surfactant 0.75% Water 4.00%
[0090] The following ingredients were weighed and combined in a
container of suitable volume:
TABLE-US-00023 MIX1 HM3PA2910(Wolff Cellulosics) 38.48 g
HM100PA2208(Wolff Cellulosics) 19.27 g HM4000PA2910(Wolff
Cellulosics) 3.24 g B700(Grain Processing Corporation) 20.32 g
Tobacco Powder (average particle size <80 .mu.m) 14.39 g
[0091] The resultant mixture was mixed until homogeneous. In a
separate container were weighed the following ingredients:
TABLE-US-00024 MIX2 Na.sub.2CO.sub.3 2.16 g Propylene Glycol
Monostearate 0.72 g Sodium Lauryl Sulfate 0.72 g
[0092] In a third container were weighed the following
ingredients:
TABLE-US-00025 MIX3 Glycerin 7.19 g Propylene Glycol 7.19 g
Polyethylene Glycol 400 7.19 g Triacetin 6.47 g Peach Puree 100.0 g
Peach Flavor 3.60 g Tobacco Flavor Modifier (Hagelin) 2.88 g
Sucralose Solution 25% (Tate & Lyle) 2.88 g
[0093] A total of 606.10 g of boiling water was weighed into a
stainless steel container. The water was stirred vigorously with an
Arrow Model 1750 high shear mixer. To the water was added MIX2.
Stirring was continued for 30 seconds, at which point was added
MIX1. Vigorous stirring was continued for 4 minutes. To the
resultant solution was added MIX3. Vigorous stirring was continued
for 1 minute. The resultant solution was transferred to a Silverson
SS1 vessel, which had been adapted for mixing under vacuum. The
vessel was attached to a Silverson L4RTU homogenizer motor unit.
The solution was homogenized under vacuum (20-25 inches of Hg) for
2 minutes at 7500 RPM, after which an ice bath was placed around
the homogenizer vessel. Homogenization continued under vacuum
(20-25 inches of Hg) for 8 minutes at 10000 RPM. After
homogenization was complete, a portion of the solution was
transferred to a 500-mL Nalgene bottle for storage.
[0094] A portion of the resultant gel solution was poured onto a
glass plate that had previously been covered with an appropriately
sized sheet of Mylar. The gel solution was drawn across the glass
plate with a draw-down knife with a fixed gap of 20 mils. The glass
plate was placed in a side-swept forced air oven (VWR model
1330FM), for 35 minutes, which had been set at 75.degree. C. The
resultant film, dried to approximately 4% moisture, was removed
from the Mylar sheet, and was stored in a plastic bag for future
use.
Example Q. Flavored/White Opaque Film for Coating
TABLE-US-00026 [0095] TABLE Q1 HPMC 45.46% Starch 15.15% Fibersol-2
10.73% Na.sub.2CO.sub.3 1.07% Plasticizer 10.73% TiO.sub.2 10.45%
Flavors 1.07% Sweetener 0.27% Surfactant 1.07% Water 4.00%
[0096] The following ingredients were weighed and combined in a
container of suitable
TABLE-US-00027 MIX1 HM3PA2910 (Wolff Cellulosics) 38.48 g
HM100PA2208 (Wolff Cellulosics) 19.27 g HM4000PA2910 (Wolff
Cellulosics) 3.24 g B700 (Grain Processing Corporation) 20.32 g
Fibersol-2 (Matsutani) 14.39 g
[0097] The resultant mixture was mixed until homogeneous. In a
separate container were weighed the following ingredients:
TABLE-US-00028 MIX2 Na.sub.2CO.sub.3 1.44 g Propylene Glycol
Monostearate 0.72 g Sodium Lauryl Sulfate 0.72 g
[0098] In a third container were weighed the following
ingredients:
TABLE-US-00029 MIX3 Glycerin 3.60 g Propylene Glycol 3.60 g
Polyethylene Glycol 400 3.60 g Triacetin 3.60 g TiO.sub.2
suspension 50% (Sensient Colors) 28.04 g Tobacco Flavor Modifier
(Hagelin) 1.44 g Sucralose Solution 25% (Tate & Lyle) 1.44
g
[0099] A total of 606.10 g of boiling water was weighed into a
stainless steel container. The water was stirred vigorously with an
Arrow Model 1750 high shear mixer. To the water was added MIX2.
Stirring was continued for 30 seconds, at which point was added
MIX. Vigorous stirring was continued for 4 minutes. To the
resultant solution was added MIX3. Vigorous stirring was continued
for 1 minute. The resultant solution was transferred to a Silverson
SS1 vessel, which had been adapted for mixing under vacuum. The
vessel was attached to a Silverson L4RTU homogenizer motor unit.
The solution was homogenized under vacuum (20-25 inches of Hg) for
2 minutes at 7500 RPM, after which an ice bath was placed around
the homogenizer vessel. Homogenization continued under vacuum
(20-25 inches of Hg) for 8 minutes at 10000 RPM. After
homogenization was complete, a portion of the solution was
transferred to a 500-mL Nalgene bottle for storage.
[0100] A portion of the resultant gel solution was poured onto a
glass plate which had previously been covered with an appropriately
sized sheet of Mylar. The gel solution was drawn across the glass
plate with a draw-down knife with a fixed gap of 20 mils. The glass
plate was placed in a side-swept forced air oven (VWR model
1330FM), for 35 minutes, which had been set at 75.degree. C. The
resultant film, dried to approximately 4% moisture, was removed
from the Mylar sheet, and was stored in a plastic bag for future
use.
Example R. Extruded Tobacco Films
TABLE-US-00030 [0101] TABLE R1 Tobacco 25.63% Klucel LF 61.53%
Na.sub.2CO.sub.3 3.32% Plasticizer 6.68% Sweetener 0.83% Water
2.00%
[0102] The following ingredients were granulated in a manner
similar to granulations utilized for tab production, as described
herein, yielding a tobacco granulation with an approximate moisture
of 4.50%:
TABLE-US-00031 Klucel LF (Hercules/Aquaon) 3448.0 g
Na.sub.2CO.sub.3 181.0 g Sucralose (Tate & Lyle) 45.0 g
Propylene Glycol 363.0 g Tobacco Powder (average particle size
<80 .mu.m) 1451.0 g Water 2344.0 g
[0103] The tobacco granulation was introduced to the feed section
of a Leistritz Micro-18 Twin Screw Extruder 40:1 L/D, which had
been configured for co-rotating extrusion with a medium-shear screw
design. Feed rates for the extrusion varied between 1-3 pounds per
hour. Barrel zone temperatures varied between 75-240.degree. F.
Venting of volatiles from the extrusion melt was accomplished by
incorporating a venting orifice prior to the discharge die of the
extruder.
[0104] Tobacco film, with a width of approximately 3 inches and a
thickness varying from 2-3 mils, was produced by incorporating a
strip die at the discharge end of the extruder. Upon discharge, the
tobacco film was calendared and cooled to room temperature by
utilizing a 3-roll stacked chill roller. Downstream from the chill
roller the film was taken up on a rewind reel, incorporating Mylar
between the film layers to prevent adhesion. The tobacco film was
placed in a container suitable for storage.
[0105] The tobacco film was subsequently used in the manufacture of
dissolvable tobacco containing pouches, as described herein. The
film disintegrated slowly in the mouth, over a period of 2-4
minutes.
Example S. Flavored Tobacco Film with Gelatin
TABLE-US-00032 [0106] TABLE S1 HPMC 35.95% Gelatin 0.98% Starch
12.30% Tobacco 23.64% Na.sub.2CO.sub.3 1.47% Plasticizer 10.84%
Flavors 9.35% Sweetener 0.50% Surfactant 0.97% Water 4.00%
[0107] The following ingredients were weighed and combined in a
container of suitable volume:
TABLE-US-00033 MIX1 HM3PA2910 (Wolff Cellulosics) 13.84 g
HM100PA2208 (Wolff Cellulosics) 7.24 g HM4000PA2910 (Wolff
Cellulosics) 1.21 g B700 (Grain Processing Corporation) 7.63 g
Gelatin 0.61 g Tobacco Powder (average particle size <80 .mu.m)
15.27 g
[0108] The resultant mixture was mixed until homogeneous. In a
separate container were weighed the following ingredients:
TABLE-US-00034 MIX2 Na.sub.2CO.sub.3 0.91 g Propylene Glycol
Monostearate 0.30 g Sodium Lauryl Sulfate 0.30 g
[0109] In a third container were weighed the following
ingredients:
TABLE-US-00035 MIX3 Glycerin 2.14 g Propylene Glycol 2.44 g
Polyethylene Glycol 400 2.14 g Mint Flavor 4.58 g Tobacco Flavor
Modifier (Hagelin) 1.22 g Sucralose Solution 25% (Tate & Lyle)
1.22 g
[0110] A total of 288.93 g of boiling water was weighed into a
stainless steel container. The water was stirred vigorously with an
Arrow Model 1750 high shear mixer. To the water was added MIX2.
Stirring was continued for 30 seconds, at which point was added
MIX1. Vigorous stirring was continued for 4 minutes. To the
resultant solution was added MIX3. Vigorous stirring was continued
for 3 minutes. The resultant solution was transferred to a suitable
container for storage.
[0111] A portion of the resultant gel solution was poured onto a
glass plate which had previously been covered with an appropriately
sized sheet of Mylar. The gel solution was drawn across the glass
plate with a draw-down knife with a fixed gap of 20 mis. The glass
plate was placed in a side-swept forced air oven (VWR model
1330FM), for 35 minutes, which had been set at 75.degree. C. The
resultant film dried to approximately 4% moisture, was removed from
the Mylar sheet, and cut into appropriately sized units. A 1.0 inch
by 1.25 inch unit of film dissolved in the mouth in less than 30
seconds, releasing flavor, sweetener, and tobacco.
Example T. Flavored Tobacco Film with Gelatin
TABLE-US-00036 [0112] TABLE T1 HPMC 32.01% Gelatin 4.92% Starch
12.30% Tobacco 23.64% Na.sub.2CO.sub.3 1.47% Plasticizer 10.84%
Flavors 9.35% Sweetener 0.50% Surfactant 0.97% Water 4.00%
[0113] The following ingredients were weighed and combined in a
container of suitable volume:
TABLE-US-00037 MIX1 HM3PA2910 (Wolff Cellulosics) 11.40 g
HM100PA2208 (Wolff Cellulosics) 7.24 g HM4000PA2910 (Wolff
Cellulosics) 1.21 g B700 (Grain Processing Corporation) 7.63 g
Gelatin 3.05 g Tobacco Powder (average particle size <80 .mu.m)
15.27 g
[0114] The resultant mixture was mixed until homogeneous. In a
separate container were weighed the following ingredients:
TABLE-US-00038 MIX2 Na.sub.2CO.sub.3 0.91 g Propylene Glycol
Monostearate 0.30 g Sodium Lauryl Sulfate 0.30 g
[0115] In a third container were weighed the following
ingredients:
TABLE-US-00039 MIX3 Glycerin 2.14 g Propylene Glycol 2.44 g
Polyethylene Glycol 400 2.14 g Mint Flavor 4.58 g Tobacco Flavor
Modifier (Hagelin) 1.22 g Sucralose Solution 25% (Tate & Lyle)
1.22 g
[0116] A total of 288.93 g of boiling water was weighed into a
stainless steel container. The water was stirred vigorously with an
Arrow Model 1750 high shear mixer. To the water was added MIX2.
Stirring was continued for 30 seconds, at which point was added
MIX1. Vigorous stirring was continued for 4 minutes. To the
resultant solution was added MIX3. Vigorous stirring was continued
for 3 minutes. The resultant solution was transferred to a suitable
container for storage.
[0117] A portion of the resultant gel solution was poured onto a
glass plate which had previously been covered with an appropriately
sized sheet of Mylar. The gel solution was drawn across the glass
plate with a draw-down knife with a fixed gap of 20 mils. The glass
plate was placed in a side-swept forced air oven (VWR model
1330FM), for 35 minutes, which had been set at 75.degree. C. The
resultant film dried to approximately 4% moisture, was removed from
the Mylar sheet, and cut into appropriately sized units. A 1.0 inch
by 1.25 inch unit of film disintegrated in the mouth in less than
30 seconds, releasing flavor, sweetener, and tobacco.
Example U. Flavored Tobacco Film with Gelatin
TABLE-US-00040 [0118] Table U1 HPMC 27.09% Gelatin 9.85% Starch
12.30% Tobacco 23.64% Na.sub.2CO.sub.3 1.47% Plasticizer 10.84%
Flavors 9.35% Sweetener 0.50% Surfactant 0.97% Water 4.00%
[0119] The following ingredients were weighed and combined in a
container of suitable volume:
TABLE-US-00041 MIX1 HM3PA2910 (Wolff Cellulosics) 8.35 g
HM100PA2208 (Wolff Cellulosics) 7.24 g HM4000PA2910 (Wolff
Cellulosics) 1.21 g B700 (Grain Processing Corporation) 7.63 g
Gelatin 6.11 g Tobacco Powder average particle size <80 .mu.m
15.27 g
[0120] The resultant mixture was mixed until homogeneous. In a
separate container were weighed the following ingredients:
TABLE-US-00042 MIX2 Na.sub.2CO.sub.3 0.91 g Propylene Glycol
Monostearate 0.30 g Sodium Lauryl Sulfate 0.30 g
[0121] In a third container were weighed the following
ingredients:
TABLE-US-00043 MIX3 Glycerin 2.14 g Propylene Glycol 2.44 g
Polyethylene Glycol 400 2.14 g Mint Flavor 4.58 g Tobacco Flavor
Modifier (Hagelin) 1.22 g Sucralose Solution 25% (Tate & Lyle)
1.22 g
[0122] A total of 288.93 g of boiling water was weighed into a
stainless steel container. The water was stirred vigorously with an
Arrow Model 1750 high shear mixer. To the water was added MIX2.
Stirring was continued for 30 seconds, at which point was added
MIX. Vigorous stirring was continued for 4 minutes. To the
resultant solution was added MIX3. Vigorous stirring was continued
for 3 minutes. The resultant solution was transferred to a suitable
container for storage.
[0123] A portion of the resultant gel solution was poured onto a
glass plate which had previously been covered with an appropriately
sized sheet of Mylar. The gel solution was drawn across the glass
plate with a draw-down knife with a fixed gap of 20 mils. The glass
plate was placed in a side-swept forced air oven (VWR model
1330FM), for 35 minutes, which had been set at 75.degree. C. The
resultant film dried to approximately 4% moisture, was removed from
the Mylar sheet, and cut into appropriately sized units. A 1.0 inch
by 1.25 inch unit of film disintegrated in the mouth in less than
30 seconds, releasing flavor, sweetener, and tobacco.
[0124] Tabs.
[0125] Compositions of the invention may also be produced as tabs,
such as super fast disintegrate (about 15 seconds), fast
disintegrate (less than 2 minutes), slow disintegrate (2-10
minutes), and chewable tabs.
[0126] Tabs may be sized as individual servings or smaller, a
plurality of which constitute an individual serving. Tabs sized as
individual servings typically have dimensions of 5 mm to 15 mm.
Smaller tabs typically range from 2 to 4 mm in diameter. Such
smaller tabs may be fabricated in a variety of colors or flavors,
e.g., for simultaneous consumption. Tabs may be shaped as a wafer,
a convex or concave pellet, ovals, or any other shape known to the
trade. Tabs may also be foamed to provide faster dissolution or
disintegration in the mouth. Tabs may also be layered to provide a
variety of tastes or mouth feels as the tab dissolves or
disintegrates. Tabs may also be coated to modify color or taste or
to provide mechanical strength for improved handling. In one
embodiment, a tab designed to disintegrate rapidly in water may be
coated with a very thin water insoluble coating to provide
protection to the tab while a second, water soluble coating is
applied.
[0127] Tabs may be fabricated from a dry mix, known as direct
compression or from pregranulated materials by any forming method
known in the art, e.g., via a press, injection molding, compression
molding, injection foam molding, or compression foam molding.
Tab Examples
[0128] The following table shows exemplary ingredients for
fabricating tabs of the invention.
TABLE-US-00044 TABLE V1 Exemplary Ex. V Ex. W Ex. X Ex. Y Range (%)
Fast (%) Fast (%) Slow (%) Slow (%) Water soluble 0-70 0 3 23 0
polymer Tobacco 1-70 27 20 27 30 Flavor Oil 0.5-4.0 2 1.8 2 2
Artificial 0.05-0.4 0.15 0.15 0.15 0.1 Sweetener Sugar 1-80 64 35
45.85 33.3 Maltodextrin 0-50 0 19 0 0 Disintegrant 0.1-15 6.35 3.0
-- -- Starch 5-80 0 17.35 -- 50 Release Agent 0.1-2.0 0.5 0.5 0.5
0.5 Emulsifier 0.1-5.0 0 0.2 0.5 0.1
Example Z. Exemplary Chewable Tab
[0129] A chewable tab can be formed using the following
ingredients: compressible sugar (40%); tobacco (20%); dextrose
(25%); maltodextrin (13%); coloring agents (0.05%); flavor (1.35%);
and magnesium stearate (0.60%).
Example AA. Thermoplastic Tab
[0130] A thermoplastic tab can be formed using the following
ingredients (in parts): hydroxypropyl cellulose (HPC) 54; tobacco
27; microcrystalline cellulose 10; propylene glycol 4; artificial
sweetener 2; flavor 2; and stabilizer 0.2. The ingredients are dry
mixed and fed to an extruder using barrel temperatures necessary to
melt the HPC (typically 340-370.degree. F.). A rod of about 1/2
inch diameter is extruded and cut to size sufficient to form a
tab.
Example AB. Tobacco Tab
TABLE-US-00045 [0131] TABLE AB1 Formulation of Tobacco Tab
Ingredients % Dry Weight Basis Tobacco Powder 25.00 Sweetener 32.11
Maltodextrin 40.22 Flavors 0.75 Emulsifier 1.36 Na.sub.2CO.sub.3
0.56 Total 100.00
TABLE-US-00046 TABLE AB2 Formulation of Binding Solution for
Production of Tobacco Tab Ingredients Percent Water 45.00
Maltodextrin 53.05 Emulsifier 1.80 Sweetener 0.15 Total 100.00
[0132] Preparation of Binding Solution
[0133] Ingredient amounts, as noted in Table AB2, were weighed out
into separate containers. Gum Arabic Pre-hydrated (emulsifier) was
slowly added to the water and mixed under high shear agitation in a
stainless steel vessel. After complete dissolution, M 585
maltodextrin (Grain Processing Corporation) was added slowly to the
water. Once M 585 was completely dissolved, the Sucralose sweetener
(Tate & Lyle) was added slowly and mixed thoroughly to ensure
complete dissolution.
[0134] Formulary amounts of peppermint and spearmint flavors and
Na.sub.2CO.sub.3 as noted in Table AB1 were added to the binding
solution. The entire mixture was homogenized for approximately 20
minutes at 9000-10000 RPMs with the aid of a homogenizer. The
proper amount of binding solution to use was determined by the
batch size and the ingredient percentages shown in Table AB1. The
homogenized solution was transferred into the flavor
holding/pumping tank.
[0135] Preparation of Dry Ingredients
[0136] The formulary amounts of mannitol (sweetener) and tobacco
powder (bone dry basis), as noted in Table AB1, were blended
together and placed in the product bowl.
[0137] Preparation of Vector Multiflo-15 Fluid Bed Chamber
[0138] A Vector Multiflo-15 fluid bed coater was used to apply the
binding solution to the dry ingredient blend to form the final
granulation. The manual process was selected on the control panel
computer. The machine operating parameters, located in Table AB3,
were loaded into the program:
TABLE-US-00047 TABLE AB3 Vector Multiflo-15 Fluid Bed Parameter
Settings Inlet Temperature (Celsius) 60 Airflow (CFM) 150 Flowrate
(G/Min) 125 Filter Pulse Interval (Sec) 30 Post-Pulse Time (Sec)
60
[0139] The appropriate amount of binding solution to be sprayed on
was also loaded into the program. The binding solution amount was
determined by the desired batch size to achieve the ingredient
percentages shown in Table AB1.
[0140] Granulation Process
[0141] Once the dry ingredients were fluidized in the fluid bed
chamber and achieved a temperature of 40-45.degree. C., the binding
solution was slowly sprayed onto the dry ingredients to form the
granulation. The nozzle pressure was set at 22 psi and airflow at
200 CFM. The airflow was increased to ensure good product movement
or fluidization in the fluid bed chamber. Once all the binding
solution had been applied, the airflow was reduced to 200 CFM. The
process was stopped once the product temperature reached
approximately 43.degree. C.
[0142] Preparation of Granulation for Forming Tabs
[0143] The granulated material was then sized through a 12-mesh
screen. The magnesium stearate (lubricant) was sized through a
40-mesh screen. The formulary amount of magnesium stearate as noted
in Table AB4 was combined with the granulated material in a plastic
bag and manually shaken for 2 minutes.
TABLE-US-00048 TABLE AB4 Formulation of Ingredients for Forming
Tabs Ingredients % Dry Weight Basis Granulated Material 99.50
Lubricant 0.50 Total 100.00
[0144] Tab Forming Process
[0145] The granulated material plus lubricant was loaded into the
hopper of the press. The following parameters noted in Table AB5
were set on the Vanguard VSP 8 Mini Rotary Press:
TABLE-US-00049 TABLE AB5 Parameters for Tobacco Tab Fast
Disintegrate Slow Disintegrate Parameters Settings Ranges Settings
Ranges Fill Depth(MM) 8.0 11.3 11.3-11.4 Thickness (MM) 1.3 1.8
Principal Pressure (KN) 5.0 10.8-12.0 Ejection Pressure (MM)
0.03-0.12
[0146] Fast disintegrate disintegrated in the mouth within 1 to 3
minutes. Slow disintegrate disintegrated in the mouth between 5-8
minutes.
Example AC. Tobacco Tab
TABLE-US-00050 [0147] TABLE AC1 Formulation of Tobacco Tab
Ingredients % Dry Weight Basis Tobacco Powder 25.00 Sweetener 34.11
Maltodextrin 38.58 Flavors 1.00 Emulsifier 1.31 Total 100.00
TABLE-US-00051 TABLE AC2 Formulation of Binding Solution for
Production of Tobacco Tab Ingredients Percent Water 45.00
Maltodextrin 53.04 Emulsifier 1.80 Sweetener 0.16 Total 100.00
[0148] The procedures previously stated in Example AB1 for binding
solution preparation were followed. Formulary amounts of peppermint
and spearmint flavors as noted in Table AC1 and 45.00 grams of
Na.sub.2CO.sub.3 were added to binding solution. The remaining
procedures for the make-up for the binding solution, preparation of
dry ingredients, preparation of Vector Multiflo-15 Fluid Bed
Chamber, and granulation process were followed.
[0149] Preparation of Granulation for Forming Tabs
[0150] The granulated material and magnesium stearate were sized
through the appropriate screens as previously stated. The formulary
amount of magnesium stearate (0.75% for a fast disintegrate or
1.00% for a slow disintegrate) was combined with the granulated
material in a plastic bag and manually shaken for 2 minutes.
[0151] Tab Forming Process
[0152] The machine operating parameters noted in Table AC3 were set
on the Vanguard
TABLE-US-00052 TABLE AC3 Tab Forming Parameters for Tobacco Tab
Fast Disintegrate Slow Disintegrate Parameters Settings Ranges
Settings Ranges Fill Depth (MM) 6.8 9.9 Thickness (MM) 1.1 2.0-2.1
Principal Pressure (KN) 6.9-7.2 3.8-4.0 Ejection Pressure (MM)
0.03-0.15
Example AD. Tobacco Tab
TABLE-US-00053 [0153] TABLE AD1 Formulation of Tobacco Tab
Ingredients % Dry Weight Basis Tobacco Powder 25.00 Filler 30.00
Maltodextrin 42.15 Flavor 0.75 Emulsifier 1.43 Sweetener 0.12
Na.sub.2CO.sub.3 0.56 Total 100
TABLE-US-00054 TABLE AD2 Formulation of Binding Solution for
Production of Tobacco Tab Ingredients Percent Water 45.00
Maltodextrin 53.06 Emulsifier 1.80 Sweetener 0.14 Total 100.00
[0154] The procedures previously stated for binding solution
preparation were followed. Formulary amounts of Cinnamon Flavor and
Na.sub.2CO.sub.3 as noted in Table AD1, were added to the binding
solution. The remaining procedures for the make-up of the binding
solution, preparation of dry ingredients (lactose filler combined
with tobacco powder), preparation of the Vector Multiflo-15 Fluid
Bed Chamber, and the granulation process were followed.
[0155] Preparation of Granulation for Forming Tabs
[0156] The granulated material and magnesium stearate were sized
through 12- and 40-mesh screens, respectively. The formulary amount
of magnesium stearate (0.50% for a fast disintegrate or 1.00% for a
slow disintegrate) was combined with the granulated material in a
plastic bag and manually shaken for 2 minutes.
[0157] Tab Forming Process
[0158] The parameters noted in Table AD3 were set on the Vanguard
VSP 8 Mini Rotary Press:
TABLE-US-00055 TABLE AD3 Tab Forming Parameters for Tobacco Tab
Fast Disintegrate Slow Disintegrate Parameters Settings Ranges
Settings Ranges Fill Depth (MM) 7.7 11.2 11.2-11.3 Thickness (MM)
1.1 1.7 1.7-1.8 Principal Pressure (KN) 5.7-6.0 3.8-4.0 Ejection
Pressure (MM) 0.03-0.08 0.03-0.17
Example AE. Tobacco Tab
[0159] The same procedures were followed for making a Tobacco Tab
in Example AD except wintergreen flavor was used in place of
cinnamon flavor.
[0160] Preparation of Granulation for Forming Tabs
[0161] The finished material was then sized through a 12-mesh
screen. The magnesium stearate was sized through a 40-mesh screen.
The formulary amount of magnesium stearate (0.50% for a fast
disintegrate or 0.75% for a slow disintegrate) was combined with
the granulated material in a plastic bag and manually shaken for 2
minutes.
[0162] Tab Forming Process for Tobacco Tab
[0163] The parameters noted in Table AE1 were set on the Vanguard
VSP 8 Mini Rotary Press:
TABLE-US-00056 TABLE AE1 Tab Forming Parameters for Tobacco Tab
Fast Disintegrate Slow Disintegrate Parameters Settings Ranges
Settings Ranges Fill Depth (MM) 8.1 12.0 12.0-12.1 Thickness (MM)
1.1 1.1-1.2 1.8 Principal Pressure (KN) 5.7 5.7-6.0 4.5 4.5-5.2
Ejection Pressure (MM) 0.03-0.09 0.04-0.19
Example AF. Tobacco Tab with an Opaque, White Coating
TABLE-US-00057 [0164] TABLE AF1 Formulation of Tobacco Tab
Ingredients % Dry Weight Basis Tobacco 25.00 Filler 30.00
Maltodextrin 39.74 Flavor 0.75 Emulsifier 1.35 Sweetener 0.10
Na.sub.2CO.sub.3 0.56 Tobacco Flavor Modifier 2.50 Total 100
TABLE-US-00058 TABLE AF2 Formulation of Binding Solution for
Production of Tobacco Tab Ingredients Percent Water 45.00
Maltodextrin 53.07 Emulsifier 1.80 Sweetener 0.13 Total 100
[0165] Preparation of Binding Solution
[0166] The procedures previously stated for binding solution
preparation were followed. Formulary amounts of apple flavor,
natural bitter blocker (Comax), and Na.sub.2CO.sub.3 as noted in
Table AF1 were added to binding solution. The remaining procedures
for the make-up of the binding solution, preparation of dry
ingredients (lactose filler plus tobacco powder), preparation of
the Vector Multiflo-15 Fluid Bed Chamber, and the granulation
process were followed.
[0167] Preparation of Granulation for Tab Forming
[0168] The finished material was then sized through a 12-mesh
screen. The magnesium stearate was sized through a 40-mesh screen.
The formulary amount of magnesium stearate (0.75% for a slow
disintegrate) was combined with the granulated material in a
plastic bag and manually shaken for 2 minutes.
[0169] Tab Forming Process
[0170] The parameters noted in Table AF3 were set on the Vanguard
VSP 8 Mini Rotary Press:
TABLE-US-00059 TABLE AF3 Tab Forming Parameters for a Slow
Disintegrate Tobacco Tab Parameters Settings Ranges Fill Depth (MM)
13.6 13.5-13.7 Thickness (MM) 2.4 2.4-2 Principal Pressure (KN)
4.5-5.2 Ejection Pressure (MM) 0.04-0.24
[0171] Tobacco Tab Coating-Suspension Makeup
[0172] A 20% Opadry II aqueous solution was prepared as directed by
the manufacturer and allowed to mix 45 minutes prior to
coating.
[0173] Coating Process
[0174] Tabs (5.5-6.5 KG) were placed in the coating pan of a
Vector/Freund Hi-Coater pan coating machine and warmed until the
exhaust temperature reached 45.degree. C. This was done with the
pan running at less than 5 RPMs to minimize Tab attrition. Air at
75.degree. C. and 100 CFM ran across the pan at a pan pressure of
-0.5'' water.
[0175] Once the tabs reached temperature, the pan speed was
increased to approximately RPMs and the Opadry coating suspension
was applied at a rate of 15-20 grams/minute. The suspension was
continually mixed during application to prevent the solids from
settling. The spray was atomized with approximately 100 liters of
air per minute at approximately 70 psi. The atomized spray was
formed into a pattern using directional air ports on the nozzle set
at approximately 50 liters of air per minute at approximately 70
psi.
[0176] Inlet air temperature was periodically increased or
decreased to maintain an exhaust temperature between 43 and
46.degree. C.
[0177] Spraying was continued until desired amount of solids was
applied to satisfy formulary requirements which was typically
around 3%, or until tabs were visually satisfactory.
Example AG. Tobacco Solid Disintegratable
[0178] The following ingredients were weighed out into individual
containers:
TABLE-US-00060 Klucel EF (Hercules) 60 g Tobacco Powder 75 g
Tobacco Flavor Modifier 6 g Corn Syrup (65%) 45 g Sucrose 45 g
B3700 (Grain Processing Corp.) 51 g Sucratose Solution 25% (Tate
& Lyle) 3 g Propylene Glycol 3 g Sodium Carbonate 1.5 g Water 6
g Oil of Peppermint 4.5 g Water portion 1 (hot) 120 g Water portion
2 (cold) 120 g
[0179] The 6 g of water was added to the sodium carbonate, and the
mixture was stirred. This mixture was allowed to stir until it was
added to the other ingredients later in the process.
[0180] Water portion 2 (cold) was placed in an ice bath to chill
while water portion 1 (hot) was heated to 60.degree. C. and
transferred to a stainless steel container. The 60.degree. C. water
was stirred with an Arrow Model 1750 high shear mixer and the
Klucel EF gradually added to the water. This solution was stirred
for several minutes. Water portion 2 (cold) was then added to the
mixture. An ice bath was placed under the stainless steel
container, and the mixture was stirred for 15 minutes.
[0181] After 15 minutes of stirring, the remaining ingredients were
added to the mixture one at a time. The mixture was thoroughly
blended prior to the addition of the next ingredient. The
ingredients were added in the following order: tobacco flavor
modifier, propylene glycol, sucralose solution, corn syrup, sodium
carbonate solution, sucrose, tobacco powder, B700, and oil of
peppermint. Ice was added to the ice bath throughout the mixing
process to keep the mixture cold. After all ingredients were added,
the mixture was stirred for an additional 10 minutes.
[0182] The container was removed from the ice bath and the mixture
was dispensed in solid disintegratable portions onto wax paper and
allowed to dry at room temperature for 24 hours. The solid
disintegratables were removed from the wax paper and transferred to
another sheet of wax paper to continue drying at room temperature.
The desired hardness for the solid disintegratables was achieved
after 12 to 24 hours of continued drying.
Example AH. Tobacco Solid Disintegratable
[0183] The following ingredients were weighed out into individual
containers:
TABLE-US-00061 HPMC 2910 HM E5/6 Bv (Celanese) 60 g Tobacco Powder
75 g Tobacco Flavor Modifier 6 g Corn Syrup (65%) 45 g Sucrose 45 g
B700 (Grain Processing Corp.) 39 g Sucralose Solution 25% (Tate
& Lyle) 3 g Propylene Glycol 15 g Sodium Carbonate 1.5 g Water
6 g Oil of Peppermint 4.5 g Water portion 1 (hot) 120 g Water
portion 2 (room temp.) 120 g
[0184] The 6 g of water was added to the sodium carbonate, and the
mixture was stirred. This mixture was allowed to stir until it was
added to the other ingredients later in the process.
[0185] Water portion 1 (hot) was heated to 80.degree. C. and
transferred to a stainless steel container. The 80.degree. C. water
was stirred with an Arrow Model 1750 high shear mixer, and the HPMC
gradually added to the water. This solution was stirred for several
minutes. Water portion 2 (room temp.) was then added to the
mixture, and the mixture was stirred for 15 minutes.
[0186] After 15 minutes of stirring, the remaining ingredients were
added to the mixture one at a time. The mixture was thoroughly
blended prior to the addition of the next ingredient. The
ingredients were added in the following order: tobacco flavor
modifier, propylene glycol, sucralose solution, corn syrup, sodium
carbonate solution, sucrose, tobacco powder, B700, and oil of
peppermint. After all ingredients were added, the mixture was
stirred for an additional 10 minutes.
[0187] The mixture was dispensed in portions onto wax paper and
allowed to dry at room temperature for 24 hours. The solid
disintegratables were removed from the wax paper and transferred to
another sheet of wax paper to continue drying at room temperature.
The desired hardness for the solid disintegratables was achieved
after 12 to 24 hours of continued drying.
[0188] A similar product was made using the same formulation,
mixing process, and dispensing process, but the solid
disintegratables were dried in a forced air oven (VWR Model 1330FM)
set at 32.degree. C. for one hour. The solid disintegratables were
then removed from the oven and dried at room temperature for 24
hours. Additionally, solid disintegratables were dried in the
forced air oven at 32.degree. C. for 18 hours. A slightly harder
solid disintegratable with a dull finish was achieved with this
drying technique.
Example AI. Multilayer Tab
[0189] Commercially available press equipment can be used to
prepare tabs with two or more distinct layers. The composition of
these layers can be the same or different in composition.
Individual layers can be differentiated by color, flavor, tobacco
type, tobacco content, dissolution rate, and other similar
characteristics. For example, one layer could disintegrate very
rapidly to release flavor or flavor masking ingredients. A second
layer containing tobacco powder could disintegrate more slowly
thereby gradually exposing the tobacco.
[0190] Shaped Parts.
[0191] Tobacco compositions may also be formed into products that
are sufficiently rigid to be easily handled. These shaped products
may vary in physical properties and range from highly flexible to
highly stiff parts. Such products may be formed into any shape and
be dense or foamed. These compositions typically have a moisture
content of 2-50%, preferably 5-10%, of the finished part weight.
Exemplary shapes include a tube, a toothpick, a stick, a twist, or
a solid rod. Typically, a shaped part will be sucked or chewed on
for an extended period of time to release tobacco organoleptic
components into the mouth. A shaped part may or may not
disintegrate orally. Parts that disintegrate may do so over a
period of 1-60 minutes, preferably from 1-10 minutes.
[0192] Shaped parts may or may not be sized to fit entirely in the
mouth. Compositions larger than the mouth may be partially
inserted. Typically the largest dimension of a shaped part is 6
inches, more preferably 2.5 inches.
[0193] Shaped parts may contain discrete regions, e.g., with each
region having the same or different flavor or color or size or form
of tobacco, e.g., tobacco perceived as soluble. For example, a
twist may contain individual strands, each having a different
flavor or color or size or form of tobacco. As further examples,
shaped parts may be prepared in multistep processes in which molded
or extruded parts are composed of layers, two or more of which
contain different flavors, colors, or sizes or forms of
tobacco.
[0194] Shaped part compositions may be fabricated by any method
known in the art, e.g., extrusion, compression molding, injection
molding, impact forming, foam molding, blow molding, and
overmolding. In addition, shaped parts may be based on water
soluble or thermoplastic formats. In one embodiment, an
aqueous-based shaped part is fabricated by forming a viscous paste
(e.g., via Hobart process) of the format, water, tobacco, and other
ingredients and pressing the paste into a form, extruding through a
die, or forming a sheet from which shapes are cut. The cut or
formed part may then be dried to the desired moisture level of from
2-50%, preferably from 5-10% of the finished part weight for very
rigid parts and from 10-50% for highly flexible parts. In another
embodiment, the aqueous paste can be formed in a two stage
extrusion process (e.g., via a Wenger twin screw extruder) in which
the format, water, tobacco, and other ingredients are blended in a
mixing or pre-extrusion stage of the machine, and the resulting
paste is fed directly to the twin screw extrusion element of the
machine and is extruded through a die to form a shape, which is
then dried to the desired moisture level. A thermoplastic-based
shaped part is fabricated, for example, by mixing components via a
PK blender, high intensity mixer, pre-pelletizer, or granulation
(fluid bed or Hobart) process. The mixed components may then be
extruded through conventional single or twin screw extruders to
form shaped parts or the mixture can be fed into injection molding
machines or other thermoplastic processing machinery to form shaped
parts.
Shaped Part Examples
Example AJ. Injection Molded Shaped Parts
[0195] The following table provides exemplary shaped parts to be
formed by injection molding.
TABLE-US-00062 TABLE AJ1 1 2 3 4 5 6 7 8 Ingredient % % % % % % % %
Tobacco 47.98 45.59 67.18 63.83 78.22 74.32 29.33 27.87 Low 48.02
45.62 28.84 27.40 19.59 18.61 68.48 65.06 viscosity HPC Water 4
3.80 3.98 3.78 2.19 2.08 2.19 2.08 Propylene 4.99 4.99 4.99 4.99
glycol
[0196] Heating zones were Zone 1--300-340.degree. F.; Zone
2--350-370.degree. F.; Zone 3-300-340.degree. F.; mold temperature
was ambient. Sufficient composition was fed to the screw to equal
one injection cycle; the material was immediately injected into the
mold; the mold was opened after 10 seconds; and the part was
removed. The shaped part was a stepped color chip, 2 inches by 3
inches by steps at 1/8.sup.th, 1/4.sup.th, and 3/8.sup.th inch
thickness.
Example AK. Compression Molded Shaped Parts
[0197] The following table provides exemplary shaped parts formed
by compression molding.
TABLE-US-00063 TABLE AK1 A B C D E F G Ingredient % % % % % % %
Tobacco 26.47 25.00 25,00 30.00 25.00 25.00 25.00 Corn starch 49.41
30.30 9.50 60.60 30.30 56.60 Starch B-820 30.30 Maltodextrin 30.30
Low viscosity HPC 45.00 Soluble fiber 30.30 30.30 Cinnamon 4.41
5.00 5.00 5.00 5.00 5.00 5.00 Flavor oil 4.41 5.00 5.00 5.00 5.00
5.00 5.00 Sucralose 0.88 0.90 0.90 0.90 0.90 0.90 0.90 Sodium
carbonate 2.65 2.50 2.50 2.50 2.50 2.50 2.50 Glycerin 1.00 1.00
2.00 1.00 1.00 5.00 Propylene glycol 11.77
[0198] 10-50 grams of water is added per 100 grams of dry
compound--sufficient to soften the mix and enable it to pass
through a pasta die mounted on a mixer. The mold parameters are as
follows:
TABLE-US-00064 TABLE AK2 Mold Temperature 220-280.degree. F.
Residence Time 5 seconds to 60 seconds Toothpick mold cavity
5/32nds inch diameter by 2 3/8.sup.th length Stick mold cavity
3/8.sup.th inch diameter by 2 3/8.sup.th length Disc mold cavity
3/4 inch diameter by 1/4 inch depth
[0199] Longer residence times produced more rigid parts, as long as
the steam was allowed to freely vent during the expansion of the
part. Additives may also be employed so that the shaped part
remains flexible after removal from the tool. The parts containing
a majority of low viscosity HPC formed excellent pieces if left in
the tool for an extended time (40 to 60 seconds). The inclusion of
plasticizer increased the rate of moisture absorption from the
atmosphere, which caused some parts to soften over time.
[0200] When the mold cavities were completely filled with molding
compound, dense and rigid parts were prepared. When the mold
cavities were filled to about 75% of the mold capacity, the
compound expanded under the pressure of expanding steam to form
foamed parts which had good rigidity, good flavor, and which
disintegrated readily in the mouth.
[0201] Foaming can be accomplished in aqueous systems by
incorporating a surface active agent (e.g., sodium lauryl sulfate)
into the mix and beating to incorporate air; foaming or aeration
can also be achieved by introducing a gas (e.g. nitrogen) to the
aqueous system while the composition is under high shear. The
aqueous system is then dried to the desired moisture level to
create a stable foamed composition. In one embodiment, an aqueous
composition is introduced to partially fill a compression mold; the
mold is closed; the mold temperature is raised above the boiling
point of water to form steam, which expands the aqueous composition
to fill the void area and to create a foamed, shaped part. For
thermoplastic systems, foaming can be accomplished by incorporating
water into the tobacco/format composition; the temperature is
raised to above the boiling point of water to form steam; and, as
the tobacco composition exits a die, the steam expands to create a
foamed structure. In another embodiment, gas (e.g., nitrogen or
carbon dioxide) is introduced into the molten, thermoplastic,
tobacco composition prior to its discharge from an extruder
resulting in a highly uniform foam structure in the shaped tobacco
composition. Other thermoplastic foaming processes well known in
the art (e.g., injection foam molding) can be used to create
foamed, tobacco compositions and shaped parts.
Example AL. Exemplary Aqueous Shaped Parts
[0202] Tables AL1 and AL2 show exemplary ingredients for
fabricating aqueous shaped parts of the invention. Sufficient water
is added to form aviscous paste.
TABLE-US-00065 TABLE AL1 Exemplary (parts) Preferred Example
Tobacco 1-80 30-50 54 Flavor 0.5-4 2.5-3 3 Insoluble Fiber 4.5-36
22.5-27 27 Water Soluble 1-50 5-20 10 CMC 7MF (medium Polymer
viscosity) Filler/Disintegrant 1-50 10-30 30 microcrystalline
cellulose Artificial Sweetener 0.05-5 0.1-2 0.2 Sucralose
Dispersant 0.1-20 0.1-2 0.2 Sodium Lauryl Sulfate
TABLE-US-00066 TABLE AL2 Exemplary (parts) Preferred Example
Tobacco 1-80 20-50 27 Flavor 0.5-4 1-3 1 Insoluble Fiber 4.5-36
9-27 9 Water Soluble Polymer 1-50 5-7.5 18 low viscosity HPC
Filler/Disintegrant 1-50 10-30 10 microcrystalline cellulose
Artificial Sweetener 0.05-3 0.1-1 0.5 Sucralose Dispersant 0.1-20
0.1-2 0.2 sodium lauryl sulfate
Example AM. Exemplary Thermoplastic Shaped Parts
[0203] Table AM1 shows exemplary ingredients for fabricating
thermoplastic shaped parts of the invention.
TABLE-US-00067 TABLE AM1 Exemplary (parts) Preferred 1 2 3 Tobacco
10-80 25-80 76.6 50 25 Plasticizer 1-20 1-20 3 4.6 5.6 propylene
propylene propylene glycol glycol glycol Water Soluble 10-80 20-50
20 30 40 Polymer Filler 0-60 0-30 -- 15 29 Stabilizer 0.1-0.5
0.2-0.4 0.4 0.4 0.4
Example AN. Tobacco Rods
[0204] A tobacco rod is made from tobacco (54 parts); flavor (2);
insoluble fiber (28); CMC (10); artificial sweetener (0.2); and
microcrystalline cellulose (30). Water sufficient to form a viscous
paste (e.g., 140 parts) is added, and the paste is suitable for
processing through an extruder. A suitable extruder would be a
Kitchen Aid mixer fitted with a pasta extruder and die. The rod
prepared from extrusion through a pasta die can then be used as the
forming mandrel for a spiral winding machine and a tobacco
containing film can be used to form a wrapping around the tobacco
core.
Example AO. Compression Molded Cinnamon Flavored Tobacco Stick
TABLE-US-00068 [0205] TABLE AO1 Tobacco 23.84% Starch 24.09% HPMC
4.97% Flavor 15.90% Filler 19.27% Na.sub.2CO.sub.3 2.98% Sweetener
0.99% Plasticizer 4.97% Water 3.00%
[0206] The following ingredients were weighed and combined in a
container of suitable volume:
TABLE-US-00069 MIX1 HM100PA2208 (Wolff Cellulosics) 11.16 g B700
(Grain Processing Corporation) 55.77 g Cinnamon Powder 24.54 g
Fibersol-2 (Matstitani) 44.61 g Na.sub.2CO.sub.3 6.69 g Sucralose
(Tate & Lyle) 2.22 g Tobacco Powder (average particle size
<80 .mu.m) 55.77 g
[0207] The resultant mixture was mixed until homogeneous. In a
separate container were weighed the following ingredients:
TABLE-US-00070 MIX2 Glycerin 11.16 g Cinnamon Flavor 11.16 g
[0208] MIX1 was added to the stainless steel mixing bowl of a
Kitchen Aid stand mixer. MIX2 was incorporated slowly to the
mixture over a time period of 3 minutes with the aid of a paddle
attachment at a medium-low speed. Following this addition, 76.92 g
of water was added to the mix in the same manner. The resulting
paste was allowed to rest at room temperature for a period of 5
minutes.
[0209] Following the rest period, the paste was fed through a 1/8
inch aperture strand forming unit which had previously been
attached to the Kitchen Aid mixer. The strands produced were cut to
between 11/2 and 2 inches in length, and stored in suitable
containers.
[0210] A set of platens with 2 inch by % inch opposing mold
cavities was heated to between 300-330.degree. F. A formed strand
was placed in the lower cavity, and the mold was closed by means of
a hydraulic press. The mold was allowed to remain closed for a
period of 30-60 seconds, providing a means for cooking the starch
component of the unit and the release of a portion of the volatile
components.
[0211] The newly formed stick, measuring approximately 2 inches by
1/8 inch, comprised a smooth rigid outer layer, and a rigid
foam-like inner mass. The unit disintegrated in the mouth over a
period of 1-2 minutes.
Example AP. Compression Molded Apple Flavored Tobacco Stick
TABLE-US-00071 [0212] TABLE AP1 Tobacco 23.84% Starch 24.09% HPMC
4.97% Flavor 6.45% Filler 19.27% Na.sub.2CO.sub.3 2.98% Sweetener
10.42% Plasticizer 4.97% Water 3.00%
[0213] The following ingredients were weighed and combined in a
container of suitable volume:
TABLE-US-00072 MIX1 HM100PA2208 (Wolff Cellulosics) 11.16 g B700
(Grain Processing Corporation) 55.77 g Sucrose 22.29 g Fiberso1-2
(Matsutani) 44.61 g Na.sub.2CO.sub.3 6.69 g Sucralose (Tate &
Lyle) 1.11 g Malic Acid 2.22 g Tobacco Powder (average particle
size <80 .mu.m) 55.77 g
[0214] The resultant mixture was mixed until homogeneous. In a
separate container were weighed the following ingredients:
TABLE-US-00073 MIX2 Glycerin 11.16 g Apple Flavor 12.27 g
[0215] MIX1 was added to the stainless steel mixing bowl of a
Kitchen Aid stand mixer. MIX2 was incorporated slowly to the
mixture over a time period of 3 minutes with the aid of a paddle
attachment at a medium-low speed. Following this addition, 76.95 g
of water was added to the mix in the same manner. The resulting
paste was allowed to rest at room temperature for a period of 5
minutes.
[0216] Following the rest period, the paste was fed through a 1/8
inch aperture strand forming unit which had previously been
attached to the Kitchen Aid mixer. The strands produced were cut to
between 1/2 and 2 inches in length, and stored in suitable
containers.
[0217] A set of platens with 2 inch by % inch opposing mold
cavities was heated to between 300-330.degree. F. A formed strand
was placed in the lower cavity, and the mold was closed by means of
a hydraulic press. The mold was allowed to remain closed for a
period of 30-60 seconds, providing a means for cooking the starch
and sugar components of the unit and the release of a portion of
the volatile components.
[0218] The newly formed stick, measuring approximately 2 inches by
1/8 inch, comprised a rigid outer layer, and a rigid foam-like
inner mass. The unit disintegrated in the mouth over a period of
1-2 minutes.
Example AQ. Extruded Tobacco Sticks
TABLE-US-00074 [0219] TABLE AQ1 Tobacco 24.34% Starch 58.48%
Na.sub.2CO.sub.3 3.17% Plasticizer 6.34% Sweetener 0.79% Flavor
4.88% Water 2.00%
[0220] The following ingredients were granulated in a manner
similar to granulations utilized for tab production, yielding a
tobacco granulation with an approximate moisture of 4.50%:
TABLE-US-00075 B700 (Grain Processing Corporation) 3327.1 g B825
(Grain Processing Corporation) 120.0 g Na.sub.2CO.sub.3 181.4 g
Sucralose (Tate & Lyle) 45.4 g Glycerin 362.9 g Tobacco Powder
(average particle size <80 .mu.m) 1451.5 g Water 3473.0 g
[0221] The tobacco granulation was introduced to the feed section
of a Leistritz Micro-18 Twin Screw Extruder 40:1 L/D, which had
been configured for co-rotating extrusion with a medium-shear screw
design. Feed rates for the extrusion varied between 1-3 pounds per
hour. Barrel zone temperatures varied between 75-100.degree. F.
Flavor application rates were established at 5 percent of the
process flow; hence cinnamon flavor was incorporated to the process
downstream of the granulation feed. Venting of volatiles from the
extrusion melt was accomplished by incorporating a venting orifice
prior to the discharge die of the extruder.
[0222] Solid tobacco sticks, with an approximate diameter of 1/8
inch, were produced by incorporating a strand die at the discharge
end of the extruder. Upon discharge, the flexible tobacco strand
was cooled to room temperature on an air-cooling conveyor and
became rigid, and was cut to approximately 2% inches in length. The
formed tobacco sticks were placed in a suitable container for
storage. The stick disintegrated slowly in the mouth over a period
of 5-10 minutes.
[0223] Gels and Gel Beads.
[0224] Compositions of the invention may also be made as gels or
gel beads. The composition may contain a soluble or insoluble gel
containing tobacco. A gel may be used to encapsulate another
material, or another material may encapsulate a gel. Gels may be
consumed in hydrated forms containing as much as 70% water. The
gels may also be dried resulting in parts containing from 1 to 70%
water. The amount of water retained in the gel depends on the
properties desired in the finished product. It is possible to
prepare tobacco containing gels that provide a wide range of
organoleptic characteristics.
[0225] Exemplary gel formats for soluble and insoluble gels include
kappa carrageenan, sodium alginate, carboxymethyl cellulose,
gelatin, pectin, agar, and starches.
[0226] Soluble gels containing tobacco can be formed by dissolving
the format and at an elevated temperature, e.g., kappa carrageenan
at 180.degree. F., and adding the tobacco powder to this solution
while continuing vigorous mixing. The hot mixture is then deposited
into a mold. Gelatin provides a weak gel at room temperature but
firmness and stability can be increased by the addition of agar or
starches. Other gelling formats may be used in a similar
manner.
[0227] Insoluble gels are formed by the addition of a cross-linking
agent to a predissolved solution or slurry. The solution is
deposited into a mold to form the desired shape and sets up through
cooling and/or drying. In most cases, it is necessary to maintain
the solution at a high temperature, e.g., greater than 180.degree.
F., to prevent premature gelation prior to deposition into the
mold. After the gel has set into its final shape, the gel can be
packaged as is or be further dried to a desired water content.
Cross-linking agents include potassium ions for carrageenan;
calcium ions for alginates and low methoxy pectins; and trivalent
ions such as aluminum for carboxymethyl cellulose. In insoluble
gels (i.e., those that do not orally disintegrate), tobacco
organoleptic compounds may leach out of the gel as it is held or
chewed in the mouth.
[0228] In one embodiment, gel compositions, e.g., beads, have a
solid or liquid center. An exemplary solid center includes
smokeless tobacco. An interior liquid may be aqueous, non-aqueous,
or heterogeneous, depending on the solubility characteristics of
the encapsulating bead wall. Aqueous based liquids are typically
encapsulated in a water-insoluble gel that can be disrupted, either
mechanically or chemically, in the mouth. The encapsulating gel
format may include a polymer and a cross linking agent. Exemplary
systems include carrageenan and a monovalent cation (e.g.
potassium), alginate or pectin and a divalent ion (e.g. calcium),
carboxymethyl cellulose and a trivalent ion (e.g. aluminum), and
gelatin and gum arabic. The center may or may not include
tobacco.
[0229] In another embodiment, a water soluble gel encapsulates a
non-aqueous filling, e.g., employing ethanol, glycol, vegetable
oil, or mineral oil. The water soluble gel and/or the non-aqueous
filling may contain tobacco and other ingredients as described
herein. Aqueous liquids may also be encapsulated in water soluble
gels by the inclusion of additives, e.g., sugars or salts, that
sufficiently bind the available water in the filling, thus,
preventing the water in the liquid from dissolving the encapsulant.
Gel encapsulants also include both hard and soft standard gelatin
capsules, which can be filled with liquids or solids.
[0230] The center of these gel compositions may or may not include
tobacco, e.g., as a tobacco slurry. The gel encapsulant also may or
may not include tobacco. An exemplary solid center includes
smokeless tobacco. The center may also include a color, sweetener,
flavor, or flavor masking agent, which may be the same or different
from that of the gel encapsulant. The rate of disintegration for
the gel encapsulant and center may also be the same or different.
Gels with centers typically have a largest dimension of at most 10
mm, e.g., at most 5 mm. Gel beads with liquid centers may be made
by introducing droplets of a tobacco/format mixture into a solution
causing gelation of the outer surface of the gel bead and retaining
the liquid center. Beads can be formed using commercial processes
developed by the Morishita Jintan Company and others and referred
to generically as "seamless liquid encapsulation" or "seamless
capsule technology." In addition, widely used methods for forming
gels of all types including beads have been developed by the
suppliers of alginate, carrageenan, and pectin polymers and are
well known in the art. The amount of gelation may be controlled,
thereby controlling the thickness of the gel encapsulant wall, by
varying the concentration of the format, the concentration of the
cross-linking agent (e.g., salt), the temperature of the
solidifying solution, and the residence time of the gel bead in the
solidifying solution. The solution may contain a cross-linking
agent or may induce gelation by other means, e.g., a temperature
change.
[0231] Solid gels may be soluble or insoluble. For solid gels, the
tobacco and format, with or without additives, are typically mixed,
and the format is allowed to gel. Soluble gels can be obtained by
using a self gelling gum, such as gellan gum or kappa carrageenan,
or by using a polymer, e.g., gelatin, that sets by a change of
temperature. Insoluble solid gels are prepared using a cross
linking agent. Such soluble and insoluble gels may be made by
introducing droplets into an oil bath, e.g., canola oil, or into an
aqueous, cross-linking bath to form a spherical shape. They may
also be made to pass through the oil into a water based
cross-linking solution. Gels may also be made in molds or may be
die cut from sheets.
[0232] In another embodiment, a gel composition is supplied as a
dry mixture of format, cross-linking agent (e.g., salt), and
tobacco, e.g., in powder form, that is solvated by the consumer
prior to use. Solvation causes the gel composition to form a solid,
which may be placed in the mouth. Typically, the user places the
dry mixture of gel ingredients in a mold and adds solvent, which
may be aqueous or non-aqueous. The mixture then quickly hydrates,
thereby forming a gel which solidifies in the shape of the mold.
The solvating liquid may be used to impart flavor or other taste or
mouth feel characteristics to the composition. Alternatively, the
consumer may place the dry mixture in the mouth for salvation. The
solvent may impart flavor or color to the composition.
Gel Examples
Example AR. Gel Beads
[0233] 100 g of 4% solution of CMC-7MF and 20 g tobacco are
combined. Drops are deposited into a 5% solution of water soluble,
edible trivalent salt (e.g., AlCl.sub.3 or
Al.sub.2(SO.sub.4).sub.3). The surface of droplets is then dried
with air drying or gentle oven drying.
[0234] 100 g of 2% kappa carrageenan and tobacco are combined and
heated to 180-190.degree. F. Drops are deposited into a cool
solution of 5% KCl.
[0235] 100 g of 4% medium viscosity sodium alginate and tobacco are
combined at 150-170.degree. F. Drops are deposited into a cool
solution of 5% edible divalent salt (e.g., CaCl.sub.2 or Ca
citrate).
[0236] Beads containing gelatin walls and tobacco slurry centers
can be prepared by depositing drops of a cold tobacco slurry (e.g.
60.degree. F.) into a slow moving stream of a dilute, warm gelatin
solution (e.g. 130.degree. F.). The warm gelatin coats the outside
of the cold droplet and as the gelatin cools and solidifies, it
forms a wall of gelatin around the liquid center.
[0237] Beads are retrieved from the solution by standard means.
Example AS. Orally Disintegrable Solid Gels
[0238] Combine 10 g gelatin and 90 g water and heat to 140.degree.
F. to dissolve gelatin. Add 20 g tobacco and pour into a mold.
Strength of the gel can be increased by substituting 6 g of gelatin
and 4 g of agar and heating to 190.degree. F. to dissolve.
[0239] Table AS1 shows exemplary ingredients for fabricating orally
disintegrable gels of the invention.
TABLE-US-00076 TABLE AS1 Example 1 (parts) Example 2 (parts)
Gelatin 8 6 Tobacco 40 40 Flavor 2 2 Insoluble Fiber 18 18
Sweetener 0.2 0.2 Agar 4 6 Soluble Fiber 15 15 Preservative 0.1 0.1
Water 200 200
Example AT. Exemplary Insoluble Solid Gels
[0240] The following tables and descriptions show exemplary
ingredients for fabricating insoluble gels of the invention, i.e.,
gels that do not orally disintegrate.
TABLE-US-00077 TABLE AT1 Carrageenan Gets Parts Kappa Carrageenan 8
Water 240 Tobacco 54 Sweetener 0.5 Soluble Fiber 27 KCl 1.5
[0241] The composition is cast at 180.degree. F. after adding KCl
and mixing thoroughly.
TABLE-US-00078 TABLE AT2 Alginate Gels Parts Sodium Alginate 10
Water 240 Tobacco 54 Sweetener 0.5 Soluble Fiber 27 CaCl.sub.2
1
[0242] The composition is cast after adding CaCl.sub.2 at
180.degree. F.
TABLE-US-00079 TABLE AT3 Carboxy Methyl Cellulose Gels. Parts
CMC-7MF 10 Water 240 Tobacco 54 Sweetener 0.5 Soluble Fiber 27
Al.sub.2(SO.sub.4).sub.3 1
[0243] The composition is cast after adding
Al.sub.2(SO.sub.4).sub.3 at 180.degree. F.
Example AU. Soluble Gels
[0244] 416 grams of aqueous 3.9% kappa carrageenan and 51.0 grams
of tobacco were combined. The solution was heated to 180.degree.
F.-190.degree. F. with stirring, and then the solution was
deposited into a mold of the desired shape. Upon cooling, the
resultant solid form was removed from the mold and dried to the
desired tobacco concentration and gel consistency.
[0245] In an alternative process, to a 1000 ml stainless steel
container equipped with an overhead mixer, mixing bar and hotplate
was added 400 ml of water at greater than 200.degree. F. The water
was continuously stirred and heated, and 16.0 g of kappa
carrageenan (Gelcarin GP 812, FMC Biopolymer) was added over 2
minutes. The resulting mixture was stirred for an additional 20
minutes, or until all kappa carrageenan was dissolved, then tobacco
was added to the homogeneous solution, and the resulting mixture
was stirred for an additional 2 minutes while maintaining an
optimal temperature of 180.degree. F. To this solution was added
0.8 g powdered Sucralose and 7.0 g cinnamon oil (Wixon Industries)
with vigorous stirring. Following an additional 1 minute of
stirring, the resulting mixture was quickly transferred via pipette
(inner diameter 0.5 cm) to Teflon-coated metal molds to obtain the
desired shape. After cooling to room temperature, the resulting
gels were removed from the molds and air dried at room temperature
for 1 h to several days until the desired consistency of the gels
was obtained.
TABLE-US-00080 TABLE AU1 Carrageenan Gels Amount parts Kappa
Carrageenan 16 Water 400 Tobacco 51 Sweetener 0.8 Cinnamon Oil
7.0
Example AV. Soluble Gels
[0246] 100 grams of aqueous 20% gelatin and 33 grams of tobacco
were combined. The solution was heated to 140.degree.
F.-150.degree. F. with stirring, and then the solution was
deposited into a mold of the desired shape. Following refrigeration
for a few minutes to a few days depending on desired firmness, the
resultant solid form was removed from the mold and dried to the
desired tobacco concentration and gel consistency.
[0247] In an alternative process, to a 400 ml stainless steel
container equipped with an overhead mixer, mixing bar and hotplate
was added 80 ml of water at 140.degree. F. The water was
continuously stirred and heated, and 20.0 g of Gelatin (Type A 250
Bloom 40 Mesh, Gum Technology) was added over 2 minutes. The
resulting solution was stirred for 5 minutes or until the gelatin
was dissolved, then 33 g of tobacco was added in portions over 2
minutes. The resulting mixture was stirred for an additional 1
minute, then 0.3 g powdered Sucralose and 1.0 g of oil of
peppermint (rectified, Blend SX 0910001, Essex Labs) were added,
and the mixture was vigorously stirred for an additional 1 minute
while maintaining a temperature of 140.degree. F. The resulting
mixture was transferred via pipette (inner diameter 0.5 cm) to
Teflon-coated metal molds to obtain the desired shape. After
cooling to room temperature, the resulting gels were removed from
the molds, and the gelatin was set by refrigeration at 40.degree.
F. for 1 hour to several days depending on desired firmness of the
finished piece.
TABLE-US-00081 TABLE AV1 Gelatin Gels Amount parts Gelatin 20 Water
80 Tobacco 33 Sweetener 0.3 Peppermint Oil 1.0
Example AW. Gel Beads
[0248] A solution of 4% sodium alginate (Keltone LV, International
Specialty Products) was prepared by adding 12 g sodium alginate to
288 g of water heated to boiling, followed by stirring and
continuous heating of water on a hot plate for 30 minutes or until
the solution was homogeneous (stock solution A). A second solution
of 0.50 M disodium hydrogen phosphate was prepared by dissolving
33.5 g disodium hydrogen phosphate heptahydrate in 200 ml of water
with warming and stirring of the resulting mixture until the salt
was dissolved, followed by adjusting the solution to 250 ml with
water. To 100 g of aqueous 0.50 M disodium phosphate was added 20
grams of tobacco and the resulting solution was stirred for 5
minutes (stock solution B). To 50 g of the resulting tobacco slurry
(stock solution B) was added 50 ml of aqueous 4% sodium alginate
(stock solution A), and the resulting mixture was stirred for 5
minutes. To flavor, 0.20 g of powdered Sucralose and 0.80 g of oil
of peppermint (rectified, Blend SX 0910001, Essex Labs) were added
to the resulting tobacco/sodium alginate slurry (solution C), and
the mixture was stirred for 2 minutes.
[0249] To prepare gel beads from solution C, a solution of aqueous
5% CaCl.sub.2 was prepared by adding 5 g of CaCl.sub.2 to 95 g of
water with stirring until the calcium chloride was dissolved
(solution D). Solution C was then added drop by drop to solution D
by pipette from a height of 10 inches. The outer coat of each
droplet solidified upon exposure to solution D, forming a solid
gel-like outer coat with a liquid center that sank to the bottom of
the calcium chloride solution. The gel beads were allowed to remain
in the calcium chloride solution for 2-4 minutes, removed, and
allowed to air dry for several minutes.
[0250] Solution A
TABLE-US-00082 Amount parts Sodium alginate 12 Water 288
[0251] Solution B
TABLE-US-00083 Amount parts Disodium hydrogen phosphate
heptahydrate 13.4 Water 86 Tobacco 20
[0252] Solution C
TABLE-US-00084 Amount parts Solution A 50 Solution B 50 Sucralose
0.2 Oil of peppermint 0.8
[0253] Solution D
TABLE-US-00085 Amounts parts Calcium chloride 5 Water 95
[0254] Consumable Units.
[0255] Compositions of the invention may also be fabricated as
consumable units. These units may be packaged as edible or inedible
materials. In one embodiment, the consumable unit includes tobacco
(e.g., smokeless tobacco) or a tobacco composition, e.g., flakes,
tabs, beads, granules, or other tobacco composition as described
herein, and a wrapping, e.g., a pouch. The wrapping, in one
embodiment, may act as an adhesive to hold the composition
together, e.g., to hold a plurality of tabs, beads, flakes, etc.
together. Alternatively, the wrapping may enclose the composition,
e.g., loose tabs, beads, flakes, etc. The composition may also
include a liquid, e.g., a tobacco slurry. The wrapping may or may
not be orally disintegrable. Orally disintegrable wrappings may be
used to enclose aqueous or non-aqueous liquids. When an aqueous
liquid is employed with a water soluble wrapping, the liquid
includes an agent to prevent dissolution of the wrapping. Exemplary
agents include sugars, salts, and other hydrophilic agents capable
of binding water sufficiently to reduce water activity to a level
at which the water is no longer available to interact with and
dissolve the water soluble wrapping. The wrapping may also enclose
a moldable tobacco composition that conforms to the mouth or holds
its shape in the mouth. In one embodiment, an orally disintegrable
wrapping encloses smokeless tobacco, e.g., dry snuff or tobacco,
that is perceived as soluble (e.g., less than 80.mu.m particle
size). Orally disintegrable smokeless tobacco compositions may be
introduced to consumable portion packs which have been formed on
continuous thermoforming or horizontal form/fill/seal equipment or
other suitable packaging equipment using edible films (which may or
may not contain tobacco) made in accordance with the subject
technology. Consumable units may also contain two or more,
individually wrapped portions of tobacco, e.g., all contained
within a larger package, one containing the other portions, or none
of the portions contained with another. When multiple portions are
used, any two may have the same or different flavor, color, form of
tobacco, or rate of disintegration.
[0256] Exemplary wrapping materials include films formed from film
compositions based on formats such as HPMC, CMC, pectin, alginates,
pullulan, and other commercially viable, edible film forming
polymers, such as those described herein. Other wrapping materials
may include pre-formed capsules made from gelatin, HPMC,
starch/carrageenan, or other commercially available materials. Such
wrapping materials may include tobacco as an ingredient. Wrappings
which are not orally disintegrable may include woven or nonwoven
fabrics; coated or uncoated paper; or of perforated or otherwise
porous plastic films. Wrappings may also be colored. Exemplary
consumable units include those formed by any method used in
commercial packaging, e.g., blister pack and stik-pak (e.g. a small
package formed on a vertical form/filL/seal packaging machine).
Consumable Unit Examples
[0257] The following description provides exemplary ingredients for
fabricating consumable units of the invention.
Example AX. Films or Capsules Encapsulating Beads, Powders, Tabs,
Etc
[0258] Any of the compositions described herein can be encapsulated
with a film or capsule. The encapsulant may provide color,
stability (e.g., during storage, handling or consumption), or
organoleptic properties (e.g., flavor, sweetness, smell, or mouth
feel). The encapsulant may also contain tobacco.
[0259] A vacuum forming tool is constructed which has a series of
cavities which are shaped as circles with diameter of 3/4.sup.th
inch and depth of 33/8.sup.th inch. Films as described herein are
prepared with and without tobacco as an ingredient. These films are
introduced to a vacuum forming machine with a vacuum forming tool.
The films are placed over heating elements and warmed to a
temperature of 200.degree. F. The films are then quickly placed on
the vacuum forming tool, and a vacuum is pulled to draw the film
into the cavities. The films are then cooled to set the shapes.
Tobacco powder is then introduced into each cavity. A second sheet
of film prepared with or without tobacco is selected and coated (by
wiping the surface of the film with a wet felt) with a thin layer
of water to create a sticky, adhesive surface. The sticky surface
is placed on top of the formed sheet wherein each cavity is filled
with a tobacco product. The sheets are pressed together to form
closed consumable units. Each cavity is then cut out of the vacuum
formed sheet to create individual units. A unit is placed in the
mouth wherein the film disintegrates and disperses the tobacco in
the oral cavity.
Example AY. Tobacco Particles in a Water-Soluble Bag
[0260] Smokeless tobacco particles or powder, e.g., snuff, may be
placed in a water-disintegrable bag. When placed in the mouth, the
bag disintegrates after a specified period of time. The bag may
contain a single serving of tobacco. It may also contain additional
additives as described herein. The tobacco may also adhere to
itself as a moldable plug once the wrapping disintegrates.
[0261] The disintegrable bag may be formed using films such as
those described herein. The film can be formed into a bag using
commercially available packaging equipment such as vertical
form/fill/seal machines (e.g. stick pack machines), horizontal
form/fill/seal machines, flow wrappers, thermoformers (blister pack
machines), and other equipment common to the art.
Example AZ. Tobacco Particles in Film/Fabric Laminations
[0262] Smokeless tobacco particles or powder may be placed in a bag
that is formed from an open or highly porous wrapping material,
e.g., fabrics, paper or plastic films, which has been laminated to
a water-soluble wrapping film. The water-soluble film layer
provides protection for the tobacco contents and prevents the
tobacco from sifting through the openings of the insoluble material
during storage and handling. Once the bag is placed in the mouth,
the water-soluble film layer dissolves or disintegrates.
Example BA. Film Pouches Containing Tobacco
[0263] Films as described herein in Film Examples N, O, P, and Q
were used to manufacture tobacco containing pouches. Individual
units approximately 1 inch by 1% inches were cut from each sheet of
manufactured film. The unit was folded over lengthwise and
heat-sealed using a Clamco Model 210-8E impulse sealer. One end of
the formed unit was also sealed in the same manner. A flavored
tobacco granulation was fed to the interior of the formed pouch,
and the final seal was made as described to seal the pouch. The
tobacco containing pouch disintegrated in the mouth between 20
seconds and 1 minute, releasing the contents of the pouch.
[0264] Insoluble Matrices.
[0265] Tobacco may also be coated onto or entrapped within an
insoluble matrix. Tobacco can be dispersed to form a slurry in an
aqueous solution of a format, as when forming a film; this slurry
can be coated on to an insoluble matrix or can be used to saturate
a porous insoluble matrix. The slurry may then be converted into a
soluble or insoluble gel or it may simply be dried to form a
coating. When a portion of this coated/saturated insoluble matrix
is placed in the mouth, leaching of organoleptic components occurs
through dissolution, chewing, or other means. In one embodiment,
tobacco in a format is introduced into a porous matrix, e.g., an
open. cell polyurethane foam or a high loft polyester nonwoven
fabric. The insoluble matrix may be placed wholly in the mouth, or
it may be disposed on a stick or other handle, which remains
partially outside the mouth during consumption. In another
embodiment, tobacco in a format is blended with an incompatible
liquid, e.g., a dispersion of carnauba wax in water, deposited in a
mold, and quickly cooled to cause a phase separation such that the
tobacco slurry is disposed within a waxy structure. These matrices
may also be chewable.
[0266] Formats for use in retaining the tobacco in the insoluble
matrix include any of the film forming polymers described herein;
any of the gelling systems described herein and any of the coating
materials described herein.
Insoluble Matrix Examples
Example BB. Polyurethane Foam A
[0267] A film forming composition which contains finely ground
tobacco as described herein is used to saturate a piece (e.g., 12
inches by 12 inches by 1 inch) of open cell polyurethane foam
(Stephenson & Lawyer, Inc. Grand Rapids, Mich.). The saturated
foam is placed on a metal tray and is put into an air circulating
laboratory oven preset at 175.degree. F. for one hour. When the
foam is removed from the oven, the tobacco containing composition
has dried to form a coating that uniformly covers all the
interstices of the polyurethane foam. The coated foam is cut into
pieces of a size (e.g., 1 inch by 1 inch by 1 inch) suitable to
place in the mouth. After use, the polyurethane foam is removed
from the mouth and discarded.
Example BC. Polyurethane Foam B
[0268] A sodium alginate and calcium salt gel composition
containing finely ground tobacco as described herein is used to
saturate an open cell polyurethane foam (e.g., 12 inches by 12
inches by 1 inch). The alginate gel is maintained at a temperature
of 180.degree. F. to prevent premature setting of the gel. The hot
alginate gel is poured on to the polyurethane foam, which is placed
on a metal tray and then quickly cooled in a refrigerator at
40.degree. F. to set the gel. The foam is then placed in a
laboratory oven preset at 175.degree. F. for 10 minutes to surface
dry the gel and to reduce moisture content to 50% based on dry
weight of the gel. The partially dried gel fills voids in the
polyurethane foam. The foam is cut into pieces and is placed in the
mouth. A further example of gels in an insoluble matrix is obtained
by drying the gel to a lower moisture content (e.g., 10% based on
dry weight of the gel). The tobacco containing gel exhibits a firm,
rubbery texture within the foam matrix and rehydrates slowly when
placed in the mouth and chewed. After use, the polyurethane foam is
removed from the mouth and discarded.
[0269] Hollow Shapes.
[0270] As discussed above, films or thin sheets of material may be
wrapped, extruded, blow molded, or otherwise shaped to form tubes,
straws, or other hollow shapes. Exemplary film or sheet materials
are disclosed in the film section herein. Such hollow shapes may be
single or multilayer. When multiple layers are used, some may
contain tobacco while others may contain colors, flavors,
sweeteners, or other compounds as described herein. Different
layers may also be employed for stability during handling or to
control disintegration during consumption. A spiral wrapped hollow
shape, e.g., tube or straw, may require an adhesive (e.g., CMC or
guar) to keep from unraveling. The layers in a multilayer hollow
shape may contain the same or different color or flavor, and such
layers may disintegrate at the same or different rates. As with
films, tobacco may also be disposed within one or more layers or
may be disposed between layers in a sandwich arrangement. The
hollow shape may also include a disintegrant to hasten
disintegration.
[0271] The compositions described above may be hollow or filled.
The filling may include tobacco, a flavor, sweetener, flavor
masking agent, or a color. The flavor or color of the filling may
be the same or different than the hollow shape. The filling is
typically a gel (solid or flowable) but may also be mechanically
rigid or may be composed of a powder or other product form.
Exemplary filling materials include gels as described herein. A
hollow shape may also be filled with a composition that
disintegrates more rapidly than the shape, e.g., to provide tobacco
at different times based on the rate of disintegration.
[0272] In one embodiment, a tobacco core (e.g., formulated with
tobacco and a format) can be extruded from a single or twin screw
extruder into a coextrusion die. In a separate single or twin screw
extruder, a water soluble, thermoplastic outer layer (e.g.,
formulated with a format and a flavor) can be introduced to the
coextrusion die to create a coated rod. A typical thermoplastic
outer layer can be provided with a formulation based on
hydroxypropyl cellulose (HPC) which is extruded at a temperature
between 220-370.degree. F. In addition, a rigid extruded tobacco
rod may become a core which is encased in a wrapped film.
[0273] In one example, a thermoplastic formulation containing
hydroxypropyl cellulose, tobacco, flavor, and sweetener can be blow
molded to form a hollow shape.
[0274] In another example, films as described herein were
additionally used to manufacture spiral-wound straws and/or sticks.
Strips of film approximately 10 inches by 3/4 inch were cut from
each sheet of manufactured film. A strip of paper of equal size was
cut and wound spirally around a 3/16 inch diameter stainless steel
mandrel. The paper was secured about the mandrel with tape on each
end. A strip of film was wound spirally about the paper in the same
fashion, overlapping each spiral by 1/16 inch. At each overlap the
film strip was glued to itself with a 30% solution of gum arabic.
The process was repeated with two additional plies of film. The
mandrel and newly formed spiral-wound film straw/stick was placed
in a side-swept forced air oven at 75.degree. C. (VWR model 1330FM)
for 15 minutes to dry. Upon removal from the oven, the spiral-wound
straw/stick was removed from the mandrel, and the paper "core"
removed from the interior of the straw/stick. The resultant
straw/stick was cut into various sizes.
[0275] For example, spiral-wound straw/stick products were prepared
using tobacco containing films as described in Example N. Flavored
Tobacco Film for Sticks/Wraps/Pouches/Vacuum Forming. Straw/stick
products containing one layer, two layers and three layers of
Example N films were prepared as described. When placed in the
mouth, the straw/stick disintegrated gradually over a period of 1
to 5 minutes.
[0276] In another example, straw/stick products were prepared using
two layers of film as described in Example N. A third layer of
film, prepared as described in Example O. Flavored/Colored Film for
Sticks/Wraps/Pouches, was provided on the top or outside of the
straw/stick. The film from Example O was red in color, cinnamon
flavored and did not contain tobacco. This straw/stick, when placed
in the mouth, disintegrated gradually over a period of 1 to 5
minutes
[0277] In another example, straw/stick products were prepared using
three layers of film as described in Example P. Peach Flavored Film
for Sticks/Wraps/Pouches. The film from Example P contained tobacco
powder and peach puree. The straw/stick was prepared as above. The
straw/stick disintegrated gradually over a period of 1 to 5
minutes.
[0278] In yet another example, straw/stick products were prepared
using three layers of film as described in Example N and Example Q.
One layer of tobacco containing film prepared in Example N was
used. A second layer of opaque, white film prepared as in Example Q
was wound over the first layer of film and offset by 1/8.sup.th
inch. A third layer of tobacco containing film as prepared in
Example N was wound over the second layer and again was offset by
1/8.sup.th inch. The affect was to provide a spiral-wound
straw/stick with a striped appearance. The straw/stick, when placed
in the mouth, disintegrated gradually over a period of 1 to 5
minutes.
[0279] In another example, hollow tobacco straws, with diameters
ranging from 1/8 to % inch, were produced by methods similar to
those employed in Example AQ of Shaped Parts; however, a tube die
was employed in the manufacture of the straw. The straw(s)
disintegrated slowly in the mouth over a period of 5-10 minutes.
Similar articles may be manufactured with a filling, with methods
known in the art (i.e. co-extrusion).
[0280] D. Modifications
[0281] Any tobacco composition described herein may be modified in
various ways. For example, a composition may be coated in single or
multiple layers. Such coatings are employed, e.g., for handling,
disintegration rate, taste, and color. Exemplary coatings include
HPMC. Coatings or decorative patterns may be applied to the surface
of the film using processes known in the art, e.g., spraying,
brushing, rol coating, doctor bar casting, slot coating, extrusion
coating, hot melt deposition, depositing particles or flakes, and
other typical methods. Coatings may be matte or glossy. A coating
may contain a color, flavor, sweetener, or flavor masking agent, as
described herein. The color, flavor, sweetener, or flavor masking
agent in the coating may be same or different as the underlying
composition. In addition, multiple coatings may also contain the
same or different color, flavor, sweetener, or flavor masking
agent. The coating may also disintegrate at a different rate than
the underlying composition. For example, a coating may disintegrate
faster than the underlying composition to provide a burst of flavor
or other organoleptic components. An orally disintegrable coating
may also be placed on a composition that does not disintegrate
orally. A coating that does not disintegrate orally may be placed
on a composition that disintegrates orally, and such a coating may
be removed, e.g., by chewing. Coatings may also be employed to
prevent evaporation of volatile components in a composition and to
prevent mechanical maceration of a composition prior to use. A
coating may also contain tobacco.
[0282] Patterns may also be printed on the surfaces of
compositions. Printing patterns also encompasses dusting or
sprinkling compounds on the surface of a composition. The pattern
may be random or in a design, e.g., a logo. All printing processes
known in the art, e.g., offset, flexographic, gravure, ink jet,
laser, screen printing, and other typical methods may be used. The
printed pattern may or may not contain a color, flavor, sweetener,
or flavor masking agent, as described herein. The color, flavor,
sweetener, or flavor masking agent in the pattern may be same as or
different from the underlying composition. In addition, multiple
patterns may also contain the same or different color, flavor,
sweetener, or flavor masking agent. The printed pattern may also
contain tobacco, e.g., up to 1-99%, preferably 10-50%. Such a
pattern may contain more tobacco, percentage-wise or in an absolute
sense, than the underlying composition.
[0283] Flakes may also be added to compositions described herein.
Flakes may be mixed into the composition, may be placed within a
void in the composition, or may be placed on the surface, e.g., and
adhered by a coating. Flakes may or may not contain a color,
flavor, sweetener, or flavor masking agent, as described herein.
The color, flavor, sweetener, or flavor masking agent in the flakes
may be same or different as the underlying composition. In
addition, multiple flakes may also contain the same or different
color, flavor, sweetener, or flavor masking agent. Flakes may also
contain tobacco, e.g., up to 99%, preferably up to 50%. Flakes may
be made by standard film forming technology as described herein.
Flakes may contain more tobacco, percentage-wise or in an absolute
sense, than the underlying composition.
[0284] Once the printed, coated, or decorated film has been
prepared, an additional layer of film may be applied to cover,
protect and seal the printed, coated or decorated surface.
[0285] Compositions of the invention may be shaped in various
forms, e.g., plants and geometric shapes (e.g., round, square,
rectangular, triangular, oval, octagonal, and the like). In
addition, compositions may contain a pattern in relief (positive or
negative) on the surface. Such a pattern may be a design, such as a
logo.
[0286] Composite compositions, i.e., compositions including two or
more of the different types of products described herein, are also
contemplated by the invention. For example, a shaped part may
contain regions of gel compositions, e.g., having a variety of
flavors. In another example, a tab may be surrounded by a gel.
Composite compositions may also have different rates of
disintegration.
[0287] E. Packaging
[0288] Individual compositions will be packaged as appropriate for
the contents of the composition. Preferably, the compositions are
stored in a waterproof case and are stable between 40 and
120.degree. F. Compositions are typically dry, flexible, and
non-adhesive while in storage. Alternatively, compositions may be
packaged using non-stick barriers, e.g., plastic film or paper,
between servings. Compositions may also be provided in a bulk form,
from which individual servings are separated.
[0289] In another embodiment, the package is water impermeable and
water insoluble, and tobacco, e.g., in liquid, slurry, or flowable
gel form, is disposed within the package, e.g., a squeezable
plastic package, a bellows, or a spray bottle, and is capable of
being dispensed into the mouth from the package. The bellows may be
compressed for oral use. Solutions or slurries are prepared for use
in a plastic bellows container or other similar consumer packaging
containers wherein the liquid is injected into the mouth by
squeezing the package. Thixotropic polymers are combined with
tobacco and other ingredients to prepare higher viscosity solutions
suitable for use in other containers. Tobacco particles can be of
greater size, but must still be small enough to pass through the
orifice of the container. For spray bottles, a stable tobacco
slurry is contained in the bottle; tobacco particles are sized to
be able to pass through a spray nozzle without blocking the
orifice; and the tobacco slurry is sprayed directly in the oral
cavity. Liquid sprays are prepared by dissolving a thixotropic
polymer such as xanthan, gellan or dextran in water and suspending
tobacco particles in a low viscosity (e.g., <50 centipoise)
solution. Other compounds, such as flavor, sweetener and
dispersant, can be added to the solution. The tobacco particles are
ground to a particle size (e.g., <80 microns) to permit the
homogeneous solution to pass through the orifice of a spray bottle.
Other packages may be otherwise squeezed or used to expel the
tobacco into the oral cavity.
[0290] F. Solutions
[0291] The following tobacco solutions may be included in any
composition described herein.
Example BD. Sprayable Solution
[0292] A solution is prepared by mixing 0.2 grams of xanthan
(Kelzan from C. P. Kelco) in 78.6 grams of cool water with vigorous
mixing for 30 minutes. To this solution is added 20 grams of finely
ground tobacco, 0.2 grams of sucralose, and 2 grams of cinnamon
flavor while continuing to mix vigorously. The solution viscosity
is adjusted with water to a viscosity of 50 centipoise.
Example BE. Thick Solution
[0293] A solution is prepared by mixing 1 gram of xanthan (Kelzan
from C. P. Kelco) with 76.8 grams of cool water while mixing
vigorously for 30 minutes. To this is added 20 grams of fine
tobacco, 0.2 grams of sucralose and 2 grams of cinnamon flavor
while continuing to mix vigorously. Solution viscosity is 1,500
centipoise.
Example BF. Paste
[0294] A paste is prepared by adding 2 grams of a medium viscosity
carboxymethyl cellulose (CMC 7MF from Hercules, Inc.) to a mixture
of 35.8 grams of cool water and 40 grams of glycerine with vigorous
mixing for 30 minutes. To this mixture is added 20 grams of fine
tobacco powder, 0.2 grams of sucralose, and 2 grams of cinnamon
flavor. A thick paste is prepared which is highly shear sensitive.
This paste can be introduced to a tube or other squeezable package
where the shear force from squeezing reduces the viscosity to
permit flow of the paste.
OTHER EMBODIMENTS
[0295] The description of the specific embodiments of the invention
is presented for the purposes of illustration. It is not intended
to be exhaustive nor to limit the scope of the invention to the
specific forms described herein. Although the invention has been
described with reference to several embodiments, it will be
understood by one of ordinary skill in the art that various
modifications can be made without departing from the spirit and the
scope of the invention, as set forth in the claims. All patents,
patent applications, and publications referenced herein are hereby
incorporated by reference.
[0296] Other embodiments are within the claims.
* * * * *