EP2742813A1

EP2742813A1 - A smoking article, such as a cigar, with flavoured mouthpiece and method for manufacturing such article

Info

Publication number: EP2742813A1
Application number: EP12196528.9A
Authority: EP
Inventors: Julien Swinnen; Ruud Hendrikx
Original assignee: Scandinavian Tobacco Group Lummen NV
Current assignee: Scandinavian Tobacco Group Lummen NV
Priority date: 2012-12-11
Filing date: 2012-12-11
Publication date: 2014-06-18

Abstract

The current invention concerns a cigar, consisting of a wrapper, binder and filler, with a distal and a proximal end forming a mouth piece characterized in that said filler for the proximal end comprises one or more natural flavoring components, homogenously dispersed within said proximal end and which are absent from the distal end.

Description

TECHNICAL FIELD

The invention pertains to the technical field of smoking articles, the primary object providing a cigar with flavored mouthpiece producing cigar rods, more specifically a tar reducing cigar comprising two different kinds of natural filler material, whereby one of the filler materials has a tar-reducing effect.

BACKGROUND

In recent years, smoking of cigars has become in vogue, and numerous cigar shops have opened around the world to satisfy this growing trend. The variety, quality and size of ready-made cigars satisfy the majority of the public.
In attempts to improve the smoking experience of cigars, various methods for altering the aroma or flavoring of the cigars have been proposed. Frequently, the cut filler (the shreds of strands of tobacco material) is treated with volatile additives such as top dressing or flavors in the form of an alcoholic solution. Casing materials, having a relatively low degree of volatility such as sugars, licorice, cocoa, essential oils, fruit extracts and humectants, are applied to the tobacco by dipping or spraying prior to the cutting or shredding operation.
U.S. Pat. No. 5,615,694 discloses a method for aromatizing the smoke of smoking articles by applying to its wrapper a solution of aromatizing substance which is transferred to the smoking article in vapor phase in the confined atmosphere of the packing of the smoking article. U.S. Pat. No. 2,947,310 discloses a dual flavor smoking article comprising a smoke flavoring medium in the form of a band encircling the tobacco filler. WO 2008 097 425 discloses a cigar provided with an elongated cigar puller device which extends into the exterior of the cigar and can be used to infuse flavorants into the cigar to alter the taste and/or aroma of the cigar.
The above mentioned methods describe a more synthetic approach for aromatizing smoking articles. While this might be found acceptable for cigarette smokers, the latter does not comply with the desires of cigar smokers which focus on the natural sensation of the smoking experience. A natural cigar typically consists out of three parts, the filler, the wrapper and a binder, which are by preference manufactured from products from the tobacco plant.
There is currently need to provide an all-natural, flavored cigar. By preference, the flavors are provided in such manner that they offer a distinguishing flavor to the rich and full aroma of the tobacco while smoking. It is hereby important that burning of the flavoring components is prevented at all cost, as the latter may cause potential health risks. In relation to the latter, there is furthermore need to provide a cigar whereby the commonly known toxic compounds such as tar, nicotine and carbon oxides, inherently related to smoking, are reduced.
The current invention aims to provide a solution for at least some of the needs mentioned above.

SUMMARY OF THE INVENTION

The present invention relates to a flavored cigar according to claim 1. By preference, the cigar is provided with natural flavoring components, solely present in the proximal end (mouthpiece) of the cigar and not in the smoking part (distal end) of the latter. As such, the acquired taste upon smoking the cigar is exclusively due to the production of volatile compounds in the smoke, and not due to the burning of the flavoring components. The latter should be avoided as it may involve health risks. In an embodiment, the natural flavoring components present in the proximal end of the cigar will be mixed with tobacco products. Moreover, due to the use of purely natural flavoring components, and 100% all-natural cigar is guaranteed. This ensures the smoking experience of the cigar, which is of great importance to cigar smokers.
In one of the embodiments, the current invention also provides for a cigar comprising a natural filter in the mouth piece, reducing the amount of toxic compounds in the smoke. By preference, the filtering effect is achieved by making use of cut, expanded tobacco stems in the mouth piece. The filtering effect of the cigar will lower the harshness of the smoke, without loss of the specific taste of the smoke. This aspect is important for the smoker, as the smoker still has to be able to appreciate the taste of a 100% natural cigar, without having to give in on the feeling and taste.
Together with the natural flavoring components in the proximal end, an all-natural cigar is created, which assures a high-quality taste and smoking experience.
In a second aspect, the current invention discloses a method for the manufacturing of a cigar according to claim 12.
Additional features and examples of the cigar and production method according to the present invention are discussed below in a non-limitative way.

DESCRIPTION OF FIGURES

Figure 1 is an overview of an embodiment of a cigar according to the current invention, showing the proximal mouthpiece comprising the flavored component and the distal smokable end.
Figure 2 is an overall overview of an exemplary apparatus to produce cigars as presented by the current invention.
Figure 3 shows a detail of the exemplary apparatus for producing cigars according to the current invention, comprising the conveyor and the format chamber.
Figure 4 is an overview of the format chamber with the pestles driven by pneumatic cylinders according to an embodiment of the current invention.
Figures 5a and 5b represent a graph depicting the reduction in percentage of NFDPM, CO and nicotine levels of cigars according to the current invention, compared to control cigars.

DETAILED DESCRIPTION OF THE INVENTION

The present invention concerns a flavoured smoking article, preferentially a cigar, whereby the produced flavor during smoking is due to the presence of natural flavoring components in the mouthpiece.
Unless otherwise defined, all terms used in disclosing the invention, including technical and scientific terms, have the meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. By means of further guidance, term definitions are included to better appreciate the teaching of the present invention.
As used herein, the following terms have the following meanings:
"A", "an", and "the" as used herein refers to both singular and plural referents unless the context clearly dictates otherwise. By way of example, "a compartment" refers to one or more than one compartment.
"About" as used herein referring to a measurable value such as a parameter, an amount, a temporal duration, and the like, is meant to encompass variations of +/-20% or less, preferably +/-10% or less, more preferably +/-5% or less, even more preferably +/-1% or less, and still more preferably +/-0.1% or less of and from the specified value, in so far such variations are appropriate to perform in the disclosed invention. However, it is to be understood that the value to which the modifier "about" refers is itself also specifically disclosed.
"Comprise," "comprising," and "comprises" and "comprised of" as used herein are synonymous with "include", "including", "includes" or "contain", "containing", "contains" and are inclusive or open-ended terms that specifies the presence of what follows e.g. component and do not exclude or preclude the presence of additional, non-recited components, features, element, members, steps, known in the art or disclosed therein.
The recitation of numerical ranges by endpoints includes all numbers and fractions subsumed within that range, as well as the recited endpoints.
The expression "% by weight" (weight percent), here and throughout the description unless otherwise defined, refers to the relative weight of the respective component based on the overall weight of the formulation.
The term natural flavoring components as used herein is to be understood as any component or derivative of such component which essentially originates from a natural product, such as a plant, fruit, tree, herb, etc. and which has the ability to flavor the smoke produced by a smoking article.
The term tobacco as used herein describes the product obtained by processing the leaves of the tobacco plant, which said process comprises the steps of harvesting the leaves of the tobacco plant, curing the said leafs, fermenting which lowers the sugar levels, moistening and stripping the leaves. In a final step, the laminas are separated from the stems, and shredded to form the tobacco which is used as filler material for cigars.
The term tobacco stems as used herein refers to the stems of the tobacco leaf, which are separated from the lamina.
The term proximal end as used herein, equals the term mouthpiece, and comprises the section of the cigar which will remain unlit. The proximal end may be provided with a filter.
The term distal end as used herein, equals the term smokable part, and comprises typically the part of the cigar minus the proximal part comprising the mouth piece. The distal end is generally provided with tobacco filler.
The term Total Particulate Matter (TPM) as used herein refers to that portion of the mainstream smoke which is trapped in the smoke trap, expressed as milligrams per cigar.
The term Dry Particulate Matter (DPM) as used herein describes the total particulate matter after deduction of its water content, expressed as milligrams per cigar.
The term Nicotine-free Dry Particulate Matter (NFDPM) as used herein describes the dry particulate matter after deduction of its nicotine content, expressed as milligrams per cigar.
The term draw resistance or pressure drop as used herein describes the static pressure difference between the two ends of the cigar when it is traversed by an air flow under steady conditions in which the volumetric flow is 17,5 ml s^-1 at the distal end.
In a first aspect, the current invention relates to a cigar, consisting of a wrapper, binder and filler, with a flavor free distal and a flavored proximal end forming a mouth piece. In particular, the filler provided for the proximal end of such cigar will comprise natural flavoring components. By preference, these natural flavoring components are only present in the proximal end and absent from the distal end. A clear visual distinction is hence present between the distal end and the proximal end, as well as a distinct separation between the two parts. The natural flavoring components are homogenously dispersed within the proximal end of the cigar. By the term 'homogenously dispersed' it is meant that the natural flavoring components are equally and to a same degree divided over the whole length of the proximal end (mouthpiece) without local concentrations of the flavoring components.
By preference, the proximal end of the cigar is provided with a self-extinguishable effect which prevents the natural flavoring components from burning. Such self-extinguishing effect may be achieved by providing a self-extinguishing composition in the filler of the proximal end or by a self-extinguishing component in the wrapper or binder at the level of the proximal end. The latter will inevitably have an impact on the natural feel of the cigar. By preference, the sorptivity of the proximal end will be higher than the sorptivity of the distal end. During the smoking of the article, TPM will build up in the proximal end, due to the filtering effect thereof. This TPM contains water. This water will create a proximal end that will not burn when the products is left after the smoking. It will also create a barrier to keep smoking when the filter is reached, due to a modified smoking sensation. The latter will be dependent on the choice of wrapper, binder and filler of the proximal end, as well as of the length and diameter (thickness) of the cigar. Hence, moisture will be retained in the proximal end of the cigar.
The whole concept of the cigar according to the current invention ensures that the developed flavors during smoking are solely due to the production of volatile compounds and not due to the burning of the natural components. The latter might cause health risks due to the production of toxic secondary compounds. Moreover, burning of the flavoring components may cause an adverse effect as these secondary compounds may attribute to a change in the anticipated taste of the natural components, hence causing an unpleasant smoking experience. These effects are to be avoided at all cost. The cigar according to the current invention ensures an improved flavor delivery during smoking. Furthermore, the cigar according to the current invention ensures minimal nuisance for the people around the smoker. The sidestream smoke will not have any significant flavor sensation, as no flavors are added to the burning part of the cigar. Only a hint of flavor exposure might be present, due to volatile components present in the exhaled smoke. However, the latter will be kept to a minimal, as the produced smoke only comprises volatile compounds and no burned matter of the natural components.
The natural flavoring components are enhancing the flavor smoke of a smoking article. These natural flavoring components may originate from the group of leaves, roots, flowers, beans, fruits, seeds, oils, spices or combinations hereof. In particular, the natural flavoring components are chosen from plant material, whereby the plant material is processed as such to be able to be embedded in the proximal end of the cigar. Said natural flavoring component may be chosen from plant material such as mint, vanilla, peppermint, anise, basil, bay leaves, cardamom, cinnamon, cedar wood, coriander, cumin, ginger, nutmeg, oregano, paprika, rosemary, saffron, sage, thyme, vanilla, lavender, licorice, coffee, tea, eucalyptus, clove, wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, rose, bergamot, cocoa, orange blossom and fruits such as citrus fruits, strawberry, apple, pear, berry fruit, etc. The mint components may be chosen from the following mint varieties: Mentha Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia, Memtha Iongifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens.
The natural flavoring components may also be understood a combination of above mentioned plant material blended with menthol and/or essential oils and/or one or more of their constituents. By preference, the natural flavoring components are prepared by finely chopping dry plant parts such as leaves, roots and/or stems. More preferably, the plant material is shredded, cut or otherwise reduced in size. By preference, the components thus received have a width of between 0.25 mm and about 3 mm, more preferably between about 1 mm and 2 mm. When the natural flavoring components comprise plant material, such material is by preference dried to a moisture content of between about 5 to 12%, more by preference of between about 8 and about 10%.
In another embodiment, said natural flavoring components may comprise granules. The latter are to be understood as discrete, solid particles formed of a compacted plant material (by preference no tobacco plant material). By compacted it is meant that the plant material has been subjected to a mechanical process to densify the plant material. In some instances the compaction disrupts the cellular structure of the plant material and causes at least a partial release of essential oils in the plant material. The plant material may furthermore be extruded.
In yet another embodiment, said natural flavoring component may comprise a liquid flavourant. For example, the proximal end may comprise tobacco product impregnated with a liquid flavourant. Liquid flavourants for use in the proximal end according to the present invention are by preference natural extracts, for instance from the group of natural flavoring components.
The improved flavor delivery of the flavored components used in the present invention may be demonstrated by calculating the amount of a compound that is released from the flavored components into the smoke per unit of bulk volume of the flavored components (referred to herein as the delivery per cubic centimeter of bulk volume). A suitable test may be set up to measure the total amount in micrograms of the compound of the flavored component that is released into the mainstream smoke of the cigar when the cigar is smoked under standardized smoking conditions. For example, during smoking, the particulate phase of the mainstream smoke may be collected in a suitable trap or filter and the collected smoke sample is then extracted in a suitable solvent and analyzed using gas chromatography to identify the levels of different compounds within the smoke.
One example of such a method for quantifying the amount of menthol released during smoking is the Menthol In Smoke (MIS) test. The skilled person will appreciate that similar tests could alternatively be used to quantify the amount of other components of flavored component that are released into the smoke.
Once the total amount of the flavor compound released into the smoke has been measured, the "bulk volume" (in cubic centimeters) of the flavored components in the cigar is then calculated by dividing the weight of the flavored components (grams) by the bulk density (grams per cubic centimeter). The delivery of the compounds per unit bulk volume is then calculated by dividing the total amount of the compound delivered into the smoke (in micrograms) by the bulk volume (cubic centimeters).
Preferably, in a smoking article according the present invention wherein the natural flavored components comprise mint leaf, the delivery of menthol per bulk volume is at least 0.05 micrograms per cubic centimeter, preferably at least 0.06 micrograms per cubic centimeter, and more preferably at least 0.07 micrograms per cubic centimeter. The amount of menthol delivered in the smoke may be at least 130 micrograms of menthol per mg of plant material, preferably at least 135 micrograms of menthol per mg of plant material, and more preferably at least 140 micrograms of menthol per mg of plant material. It is important to note that due to the fact that the natural flavored components are only provided in the proximal end (mouthpiece), the obtained flavor will be solely due to the generation of volatile compounds and not due to the burning of the flavoring component itself. The latter provides an improved flavor delivery.
Preferably, the bulk density of the natural flavoring components lies between 0.10 and 2.2 grams per cubic centimeter. More preferably, the bulk density lies between 0.20 and 0.80 grams per cubic centimeter, more preferably between 0.30 and 0.50 grams per cubic centimeter. The term 'bulk density' as used herein refers to the mass of the flavoring components divided by the volume occupied by those components. In the context of the present invention, the values of bulk density referred to correspond to the Carr Loose Bulk Density of the granules. A suitable method for determining the Carr Loose Bulk Density of the flavored components is described in ASTM standard D 6393-08. In this method, a measurement is obtained by sieving the sample of flavored components through a vibrating chute to fill a measuring cup of a known volume. The mass of the flavored components within the cup is then measured and this is divided by the volume of the cup to arrive at the bulk density.
In one embodiment, the proximal end of the cigar will entirely consist of these natural flavoring components. For instance, a proximal end (the mouthpiece) may consist 100% of dried and cut mint leaves or a combination of such mint leaves with other natural flavoring components chosen from the group as mentioned above.
In another embodiment, the filler for the proximal end comprises a tobacco product. The natural flavoring components are by preference homogenously interspersed within the filler material. In a more preferred embodiment, the ratio between the natural flavoring component and the tobacco product lies between 1:10 and 10:1, more preferably between 1:5 and 5:1, more preferably between 1:5 and 1:1. The latter allows an ideal smoking experience of the flavored cigar with an optimal flavor production. By preference, the particle size of both the natural flavoring components and the tobacco product will be similar in size. By preference, both will have a width of between 0.25 mm and about 3 mm, more preferably between about 1 mm and 2 mm.
In one embodiment, said filler for the proximal end comprises tobacco leaves, such as high-quality tobacco. By preference, this is the sole filler for the cigar, both for the distal (smokable end) as for the proximal end (comprising the mouthpiece). In one embodiment, the cigar is a Long filler cigar. In a more preferred embodiment, the cigar is a Short filler cigar. By preference, the filling power of such filler lies between 650 and 850 cm³/100g, for instance 770 cm³/100g.
By preference, the mixture of natural flavoring components and tobacco products will have a filling power of between 400 and 850 cm³/100g.
Alternatively, in a more preferred embodiment, said filler for the proximal end comprises expanded, cut tobacco stems. In particularly preferred embodiment, the filler for the proximal end has a reducing effect on the smoke yield of the cigar. The latter may account as a natural filter for the cigar. Health risks correlated with smoking are generally acknowledged and the presence of a filter in a smoking article is known to reduce the concentration of the toxic compounds (tar, nicotine and carbon oxides) causing the latter. However, cigars are seldom provided with a filter as they seem to be less attractive for the market. The smoker often objects to the presence of a filter as he fears that the latter will change the rich and full aroma of a cigar. Furthermore, the addition of a filter, which often consists out of a cellulose acetate wrapping, alters the cigar visually. A cigar provided with an all-natural filter, which does not visibly alter neither the look of the cigar nor the smoking experience, is therefore desired.
In the manufacture of cigars, the tobacco leaf is processed to separate the stems from the lamina. The lamina are shredded and are per definition considered as the high-quality tobacco used for making the smokable part of a cigar. The stems are not successfully utilizable in the manufacturing of cigars because of their relatively large diameter, their hard nature and poor burning properties. However, it was found by the inventors that the latter comprise good filtering properties and could as such be used for the manufacture of an all-natural cigar with filtering effect.
In the present invention, the tobacco stems are preferably expanded. In carrying out the expansion process of these cut tobacco stems, at first the stems separated from tobacco leaves by threshing in a customary way are shredded to a suitable dimension. More specifically, the stem gets moistened, then flattened with rollers and afterwards cut. The expanding treatment is carried out under high temperature, for instance by use of super-heated steam. The cut stems go through an expansion unit based on steam and from there to the dryer. The process can be carried out by use of Sagemueller's Vibration Tunnel VFC, which comprises a heat-insulated tunnel section which incorporates a series of closely spaced, high-quality and exchangeable nozzles arranged side-by-side. These nozzles blow super-heated steam in the form of a tightly bundled and intensive jet through the in-fed material. Finally, the stems are dried.
In a preferred embodiment, the filling power of said tobacco stems lies between 500 and 700 cm³/100g, more preferably 600 cm³/100g. The latter allows an optimal filtering effect of the mouth piece, without altering the smoking experience for the smoker.
In general, differences in filler density will be observed in the distal end compared to the proximal end. The latter are mainly due to the amount of pressure that the fillers receive during the manufacturing of the cigar. Preferably, a pressure of 0.7 to 1.25 bar will be exerted on the filler of the distal end, more preferably 1 bar, whereas the proximal end will receive a pressure of 0.2 to 0.75 bar, more preferably 0.5 bar.
When using the filtering tobacco stems in the proximal end, the distal end will be provided with a high-quality tobacco leave product for producing the smokable part of the cigar. As such, a cigar rod, comprising two different sorts of filler, one for the smokable part and one for the mouthpiece is created. As mentioned above, the filler for the proximal end is interspersed with natural flavoring components. Hence, an all-natural cigar with filtering effect and flavored smoke experience is created.
In general, the proximal end will be smaller in size compared to the distal end (smokable part) of the cigar. The size of the cigar rod preferably lies between 100 and 130 mm. In a preferred embodiment, the distal end of the cigar rod will comprise around 65 to 90% of the entire length of the cigar rod, more preferably 75%. The proximal end will comprise around 10 to 35% of the entire length of the cigar rod, more preferably 25%. Typically, the weight of the cigar will comprise between 0.8 and 15 gram.
Figure 1 depicts a schematic overview of the cigar as presented by the current invention. In general, the filler for both the flavoured proximal end (1) and the non-flavoured distal end (2) is enwrapped by a wrapper (14) and binder (13). By preference, the latter both comprise tobacco leaves. In one embodiment, the cigar may contain rows of perforations along the mouthpiece. These perforations will permit air supply during the smoking of the cigar and the amount of perforations has equally an influence on the draw resistance of the cigar. The amount and size of the perforations is directly proportional to the amount of ventilation. In general, a well-defined amount and size of perforations can optimize the smoking enjoyment, as well as lower the smoke yields of the product. The perforation pattern can vary from 0 to more than 3x14 holes, and every combination thereof in between. In one embodiment, the cigar contains 2 rows of each 7 perforations.
By preference, the draw resistance of the flavoured cigar with cut tobacco stem filter, will comprise between 45 and 65 mmWg in the distal end (smokable part), and between 95 and 120 mmWg in the proximal end (mouthpiece). If no filter is provided, the overall draw resistance in the cigar will lie between 45 and 120 mmWg, more by preference between 80 and 100. Determination of the draw resistance of the cigar and filter section occurred according to CORESTA Recommended Method N° 41 for filter rods and cigarettes (2007). The draw resistance was measured by a measuring device of the brand Sodim.
In a second aspect, the current invention equally provides for a method to produce a flavored cigar.
Generally, the method comprises the following steps:

a. Providing fillers for both the non-flavored distal end (comprising the natural flavoring components) and the flavored proximal end of the cigar. By preference, these two fillers have a different filling power. Said filler for the proximal end comprises one or more homogenously dispersed natural flavoring components, which are absent from the filler of said distal end. By preference, if a filler comprising natural flavoring components intermixed with tobacco product is desired, mixing of these ingredients will occur prior to the manufacturing of the cigar. As such, the filler for the distal end will be a blend of a tobacco product and a natural flavoring component. In the latter case, the natural flavoring component and the tobacco product is by preference provided in a ratio between 1:10 and 10:1, more preferably between 1:5 and 5:1, more preferably between 1:5 and 1:2.
b. Exerting a variable pressure on the filler for the distal end and the filler for the proximal end. By preference, a lower pressure will be exerted on the filler for the proximal end, compared to the pressure exerted on the one for the distal end. In an embodiment, a pressure of 0.7 to 1.25 bar will be exerted on the filler of the distal end, more preferably 1 bar, whereas the proximal end will receive a pressure of 0.2 to 0.75 bar, more preferably 0.5 bar.
c. Enwrapping fillers with a binder and wrapper. Wrapper and binder are typically made from tobacco leaves, and enwrap the filler to keep the filler together and to ensure the form of the cigar.
d. Applying perforations to the proximal end of the cigar.

The apparatus used to carry out the abovementioned method and to manufacture the cigar as presented in the current invention will require means to provide the two different sorts of filler and means to compress each type of filler independently of one another.
Therefore, an apparatus to produce the cigars as currently presented is provided with two distinct filler suppliers, two bunkers and a format chamber divided in two separate parts to comply with the demand. Figures 2-4 represent schematic overviews of the apparatus or parts of the apparatus as presented in the current invention.
Referring to figure 2, the tobacco filler is delivered in bags or containers (3) to the installation. These bags or containers (3) are installed above the installation by a tackle. The filler material is collected by a funnel (15) which contains combs driven by pneumatic cylinders (not shown). These combs will separate the clumps of tobacco material. From the large funnel, the tobacco material will enter a smaller funnel which ends on the supplying means towards the format chamber. The filler for the distal and the proximal end are supplied to the format chamber (6). In a preferred embodiment, these supplying means comprise a conveyor, subdivided in two separate parts for holding the different kinds of fillers. In another preferred embodiment, the supplying means comprise two separate conveyors (4, 5). Referring to figure 3, the conveyor transporting the filler for the distal end (4) will preferentially be larger in width than the conveyor transporting the filler for the proximal end (5).
In a preferred embodiment, the conveyor will be installed in an angle of approximately 30°. The conveyor is motorized, for instance driven by a stepper motor. In one aspect, the surface of the conveyor comprises studs, to prevent the filler from clumping. In another aspect, a scraper is installed above the conveyor, again for preventing the filler from clumping and to evenly distribute the filler before entering the format chamber (not shown). The scraper is driven by a rotary cylinder with a radius of 180° which determines the position of the scraper. Depending on the position and angle of the scraper, and the speed and timing of the conveyor, the amount of filler that enters the format chamber is regulated.
At the end of the conveyor, the filler is entering the format chamber (6). In one embodiment, this occurs through a valve which regulates the amount of filler entering the format chamber by opening or closing. In a preferred embodiment, a hopper (7) is installed at the end of the conveyor. The filler will enter the format chamber (6), which is smaller than the conveyor, through the hopper (7).
The format chamber (6) will determine the format of the cigar, such as length and thickness. As the cigar to be produced by the apparatus comprises of two different kinds of filler, the filler cannot be mixed upon entering the format chamber. Therefore, in a preferred embodiment, the format chamber is divided in to sub-compartments, entirely separated from one another. The separation between the different compartments consists out of a vertical partition wall (16) placed in the format chamber.
Referring to figure 4, in a preferred embodiment, the pestles (8, 9) driven by pneumatic cylinders (10) with sensors (17), are installed above the format chamber for volume and weight measurement. A specific amount of filler will enter the format compartment coming from the hopper at the end of the conveyor. The right amount of filler that enters the format compartment is determined by the position of the pestle in the compartment. This position is determined by analogue sensors (17). The format chamber is movable in a vertical direction through guide rods. When a new supply of filler is needed, the format chamber will move upwards towards the hopper (7). When the format chamber (6) reaches this end position, a valve, normally closing the format chamber, will open, and the filler can enter the different compartments of the format chamber. Afterwards, the format valve will close again, and the format chamber will move downwards. When the format valve is entirely closed, the pestles (8, 9) will be pushed downward by the action of the pneumatic cylinders. The tightness of the tobacco parts in the cigar is determined by applying a certain pressure on the format cylinder, so the size of either one of the filler in the format compartments is consistent and depending on this pressure. Applying a low pressure (0-0.5 bar) to the filter compartment, results in a very low packed filter. Applying higher pressures (up to a few bars, preferentially 1 bar) results in a very tightly packed filter. The tightness of the filter determines the final smoke composition and smoking experience.
The format pestle will push a certain amount of filler out the format compartments. Simultaneously, the format knife (18), installed underneath the format chamber, will swing away, aided by the arms connected to the knife. When the right amount of filler is pushed out of the format chamber, the knife (18) will swing back, and the cut-off filler will fall on the wrapping table (12) underneath the format chamber. Afterwards the tobacco material can now be enwrapped by binder (13) and wrapper (14), which will lead to a finished cigar.
The installation is built in such a way, that the format chambers are interchangeable; hence one installation can support the production of different cigar formats.
It is supposed that the present invention is not restricted to any form of realization described previously and that some modifications can be added to the presented example of fabrication without reappraisal of the appended claims.
The invention is further described by the following non-limiting examples which further illustrate the invention, and are not intended to, nor should they be interpreted to, limit the scope of the invention.

EXAMPLES

Flavored cigar with filter

As mentioned, the expanded, cut tobacco stems provide for a reducing effect of the smoke components, more specifically NFDPM (tar), nicotine and carbon monoxide. This was confirmed by specific measurements, whereby the levels of these components were measured in the cigar according to the current invention and in a reference cigar. Prior to the measurement of these components, the cigars were conditioned for minimal 48 hours in a room with constant temperature of 22°C, an atmospheric pressure 96 kPA and a relative air humidity of 60%.
All measuring methods were performed according to the CORESTA Recommended Methods as listed on their website. More specifically, the determination of TPM occurred according to CRM Nr. 65. The determination of nicotine occurred according to CRM Nr. 66. The determination of water occurred according to CRM Nr. 67. The determination of CO occurred according to CRM Nr. 68. The levels of the smoke compounds were measured with the use of a Borgwaldt KC smoke analyser. In general, by use of expanded, cut tobacco stems, the levels of tar (NFDPM) could be reduced by 10 to 60%, with an overall average of 35% compared to the reference cigar. The CO and nicotine levels could respectively be reduced by 20 to 40%, overall average by 30% and by 35 to 50%, overall average 40%.
Furthermore, the inventors found that cut tobacco stems of the filter material formed an effective mechanical filter for the particles in the smoke, as well as for vapor phase constitutes such as hydrogen cyanide, formaldehyde and other volatile aldehydes.
The smoke compounds of two populations of cigars of a given type were tested in a smoke analyzer according to the CORESTA recommended guidelines. Population A comprised of 20 cigars of type 1, sampled from a population of 1000 cigars (specifications see below), while population B comprised of 20 cigars of a given type 2, sampled from a population of 1000 cigars (specifications see below). For comparison reasons, a population of filter-less counterparts of each cigar type was used as control. The cigars of the population to be analyzed were randomly chosen within the group of cigars of a given type. Sampling occurred through the recommendations given by CORESTA recommended method n°47 (2000).
A cigar of given type 1 according to the present invention with the following parameters:

total weight: 3.6 ± 0.45 g
total length: 121.5 ± 1.5 mm
weight mouthpiece: 0.95 ± 0.7 g
weight smokable part: 2.65 ± 0.2 g
diameter: 12.8 ± 0.3 mm
diameter of head piece: 8.5 ± 0.5 mm
perforations: 1 x 2 x 7

A cigar of given type 2 according to the present invention with the following parameters:

total weight: 1.65 ± 0.2 g
total length: 105 ± 1 mm
weight of mouthpiece: 0.49 ± 0.035 g
weight of smokable part: 1.025 ± 0.08 g
diameter: 9.4 ± 0.2 mm
diameter of head piece: 6 ± 0.4 mm
perforations: 1 x 2 x 7

The values of all the measurements performed for each cigar type are shown below in Table 1.

Table 1. NFDPM, CO and nicotine content of cigars according to the presented invention compared to control cigars (mg/g)

	Cigar Type 1	Control Type 1	Cigar Type 2	Control Type 2
NFDPM (mg/g)	14 ± 2.0	23 ± 1.5	8 ± 1.2	15 ± 0.6
CO content (mg/g)	27 ± 2	36 ± 2	22 ± 1	36 ± 1
Nicotine content (mg/g)	1.25 ± 0.1	2.1 ± 0.1	0.75 ± 0.1	1.3 ± 0.1

Figure 5 shows graphs which depicts the percentage of reduction of NFDPM, CO and nicotine levels in the cigars according to the invention compared with control cigars, based on the results obtained in Table 1.

Claims

A cigar, consisting of a wrapper, binder and filler, with a flavor free distal and a flavored proximal end forming a mouth piece characterized in that said filler for the proximal end comprises one or more natural flavoring components, homogenously dispersed within said proximal end and which are absent from the distal end.
Cigar according to claim 1, characterized in that said filler for the proximal end further comprises a tobacco product.
Cigar according to claim 2, characterized in that the ratio between said natural flavoring component and the tobacco product lies between 1:10 and 10:1.
Cigar according to any of the claims 1 to 3, characterized in that said filler for the proximal end is self-extinguishable.
Cigar according to any of the claims 2 to 4, characterized in that said mixture of natural flavoring components and said tobacco product has a filling power of between 400 and 850 cm³/100g.
Cigar according to any of the claims 1 to 5, characterized in that said natural flavoring component is chosen from the group of leaves, roots, flowers, beans, fruits, seeds, oils, spices or combinations hereof.
Cigar according to any of the claims 1 to 6, characterized in that said filler for the proximal end comprises tobacco leaves.
Cigar according to claim 7, characterized in that the filling power lies between 650 and 850 cm³/100g.
Cigar according to any of the claims 1 to 6, characterized in that said filler for the proximal end comprises expanded, cut tobacco stems.
Cigar according to claim 9, characterized in that the filling power of said tobacco stems lies between 500 and 700 cm³/100g.
Cigar according to any of the claims 1 to 10, characterized in that said distal end comprises perforations in said wrapper and binder.
Cigar according to any of the claims 1 to 11, characterized in that the draw resistance in the proximal end lies between 95 and 120 mmWg and in the distal end between 45 and 65 mmWg.
A method for manufacturing a cigar according to any of the claims 1 to 12, providing separately a filler for the flavored proximal end and one for the non-flavored distal end of the cigar, characterized in that said filler for the proximal end comprises one or more homogenously dispersed natural flavoring components, which are absent from the filler of said distal end and optionally a tobacco product.
The method according to claim 13, providing the natural flavoring component and the tobacco product in a ratio between 1:10 and 10:1.
The method according to any of the claims 13 to 14, applying perforations to the proximal end of the cigar.