EP4676246A1

EP4676246A1 - Aerosol generating material

Info

Publication number: EP4676246A1
Application number: EP24712915.8A
Authority: EP
Inventors: Samuel KAISER; Priscila BRASIL DE SOUZA CRUZ; Luiz Eduardo Biazi; Bruna Frielink IMMICH; Magnos SILVA; Gilson RUFINO DE SANTANNA; Fabio Ramos; Elizandro JESUS
Original assignee: British American Tobacco Investments Ltd
Current assignee: British American Tobacco Investments Ltd
Priority date: 2023-03-09
Filing date: 2024-03-08
Publication date: 2026-01-14
Also published as: CN121368436A; KR20250147687A; TW202547371A; GB202303474D0; JP2026509199A; WO2024184656A1

Abstract

Aerosol generating materials comprising botanical material and methods of manufacturing such aerosol generating materials are disclosed. The methods comprise providing an initial material comprising particulate botanical material and processing the initial material by subjecting the initial material to an increased mechanical pressure to produce the aerosol generating material.

Description

Aerosol Generating Material

Technical Field

The present disclosure relates to an aerosol generating material comprising botanical materials, and a method of manufacturing such materials.

Background

Aerosol generating materials are typically heated, to form an aerosol, which may be inhaled by a consumer. Aerosol generating materials may be made from various different sources, including from reconstituted tobacco material.

Summary

According to a first aspect of the present disclosure, there is provided a method of manufacturing aerosol generating material, the method comprising: providing an initial material comprising at least 20%, by mass, of particulate non-tobacco botanical material; and processing the initial material by subjecting the initial material to an increased mechanical pressure to produce the aerosol generating material; further comprising at least one of: applying an additive selected from an aerosol forming material, an active substance, and a binder, to the initial material prior to or while subjecting the initial material to the increased mechanical pressure; and applying an additive selected from an aerosol forming material, an active substance, and a binder to the aerosol-generating material after subjecting the initial material to the increased mechanical pressure.

The method may further comprise applying an additive selected from an aerosol forming material, an active substance, and a binder, to the aerosol-generating material after subjecting the initial material to the increased mechanical pressure.

The aerosol generating material maybe a non-continuous aerosol generating material.

Thus, the method may be a method of manufacturing non-continuous aerosol generating material. The initial material may comprise less than 6o%, by mass, of tobacco material.

SUBSTITUTE SHEET (RULE 26) The initial material may comprise more than 30%, by mass, of particulate non-tobacco botanical material.

The aerosol generating material may contain no tobacco material.

The particulate non-tobacco botanical material may be a material derived from species which are members of the Asteracae family, the Fabaceae family, the Myrtaceae family, Apiaceae family, Camellia taliensis, the Solanaceae family, the Brassicaceae family, the Caricaceae family, the Asclepiadaceae family, the Equisetaceae family, the Oleaceae family, the Lamiaceae family, and tisanes.

The particulate non-tobacco botanical material may be selected from the Matricaria species, such as chamomile; the Pimpinella anisum species, such as anise; the Foeniculum vulgare species, such as fennel; jasmine; lavender; cloves; eucalyptus, and the species Aspalathus linearis, such as rooibos.

The particulate non-tobacco botanical material may comprise mint, eucalyptus, lavender, ginger, cinnamon, rooibos, and/or clove material. In some embodiments the initial material further comprises non-tobacco cellulose fibre. The initial material may comprise at least 5%, by mass, of cellulose fibre. The initial material may comprise 5-20%, by mass, of cellulose fibre.

The method may further comprise combining the botanical material with the non- tobacco cellulose fibre to provide the initial material, wherein the initial material comprises at least 50%, by mass, of the particulate non-tobacco botanical material.

The method may further comprise: processing the initial material by: setting the initial material to a predefined moisture content; subjecting the initial material to an increase in temperature; and subjecting the initial material to the increased pressure in order to bind the particulate non-tobacco botanical material to the non-tobacco cellulose fibre to produce the aerosol generating material.

SUBSTITUTE SHEET (RULE 26) The particulate non-tobacco botanical material and the non-tobacco cellulose fibre may each be pre-sized and have particle size distributions that substantially overlap or correspond in size. According to a second aspect of the present disclosure, there is provided a method of manufacturing aerosol generating material, the method comprising: providing an initial material comprising particulate tobacco botanical material and non-tobacco cellulose fibre, wherein the initial material comprises at least 20%, by mass, of particulate tobacco botanical material; and processing the initial material by subjecting the initial material to an increased mechanical pressure to produce the aerosol generating material; further comprising at least one of: applying an additive selected from an aerosol forming material, an active substance, and a binder, to the initial material prior to or while subjecting the initial material to the increased mechanical pressure; and applying an additive selected from an aerosol forming material, an active substance and a binder to the aerosol-generating material after subjecting the initial material to the increased mechanical pressure. The method may further comprise applying an additive selected from an aerosol forming material, an active substance, and a binder, to the aerosol-generating material after subjecting the initial material to the increased mechanical pressure.

The aerosol generating material maybe a non-continuous aerosol generating material. Thus, the method may be a method of manufacturing non-continuous aerosol generating material.

The method may further comprise: processing the initial material by: setting the initial material to a predefined moisture content; subjecting the initial material to an increase in temperature; and subjecting the initial material to the increased pressure in order to bind the particulate tobacco botanical material to the non-tobacco cellulose fibre to produce the aerosol generating material.

SUBSTITUTE SHEET (RULE 26) The initial material and/or the aerosol generating material may comprise at least 5%, by mass, of non-tobacco cellulose fibre.

The non-tobacco cellulose fibre may comprise or consist of wood pulp.

The initial material may comprise 5-20%, by mass, of non-tobacco cellulose fibre.

The non-tobacco cellulose fibre maybe pre-sized and have a Dpgo value of between 130 micrometres and 200 micrometres, a Dpso value of between 50 micrometres and too micrometres, and a Dpio value of between 10 micrometres and 50 micrometres.

The initial material and/or the aerosol generating material may comprise the aerosol forming material in an amount of greater than 3% or 4% by mass, preferably greater than 5% by mass, such as 10-25% by mass.

The initial material and/or the aerosol generating material may comprise the aerosol forming material in an amount of 15-20% by mass.

The aerosol forming material may comprise glycerol, propylene glycol, or a mixture of glycerol and propylene glycol.

The initial material and/or the aerosol generating material may comprise the binder in an amount of up to 25% by mass. The binder may comprise carboxymethyl cellulose (CMC), starch, guar gum, xanthan gum, acacia gum and/or hydroxypropyl cellulose (HPC).

The initial material and/or the aerosol generating material may comprise 10-20% by mass, preferably about 15% by mass, of aerosol forming material, such as glycerol, and the filling value of the aerosol generating material in these embodiments may be 40-46 cm3/iog. The initial material and/or the aerosol generating material may comprise 2- 10% by mass, preferably about 5% by mass of binder. The binder may comprise CMC.

The initial material and/or the aerosol generating material may comprise 2-10% by mass, preferably about 5% by mass, of aerosol forming material, such as glycerol, and the filling value of the aerosol generating material in these embodiments may be

SUBSTITUTE SHEET (RULE 26) greater than 45 or 46 citf/ 10g. The initial material and/or the aerosol generating material may comprise 2-10% by mass, preferably about 5% by mass of binder. The binder may comprise CMC. The active substance may be selected from nutraceuticals, nootropics and psychoactives.

The active substance may comprise nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations, or one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical.

The active substance may comprise nicotine or a nicotine salt. The nicotine salt may be selected from nicotine benzoate, nicotine levulinate, nicotine citrate, nicotine lactate, or combinations thereof.

The initial material and/or the aerosol generating material may comprise nicotine in an amount of up to 3%, by weight. The initial material and/or the aerosol generating material may further comprise an acid.

The initial material and/or the aerosol generating material may comprise an acid in an amount of from about 0.1% to about 5% by weight.

The acid may comprise one or more acids selected from lactic acid, benzoic acid, citric acid, levulinic acid, 2-methylbutyric acid, and 2-methylvaleric acid.

The aerosol generating material may have a Dpgo value of between 1.2mm and 6.0mm, a Dpso value of between 1.1mm and 2.4mm, and a Dpio value of between 0.2mm and 1.5mm.

The aerosol generating material may have a fill value of greater than 25 cm3/iog, such as greater than 30 citf/ 10g. The aerosol generating material may have a filling power of 25-50 cm3/ 10g, such as 27-48 cm3/ 10g, or 29-45 cm3/ 10g.

SUBSTITUTE SHEET (RULE 26) Processing the initial material may comprise conveying the initial material through a conveyor which builds up a mechanical pressure, wherein the conveyer is operated at a throughput of 25-75 kg/hr. Processing the initial material may comprise the use of a water flow rate of less than 12 L/h.

Processing the initial material may comprise pressurising the initial material to a pressure in the range of 15-35 bar.

The method may comprise extrusion and cutting of the material in a single process.

The method may further comprise feeding the processed material through a shearing gap, wherein the shearing gap is arranged between shearing surfaces, wherein a rotatable shearing member comprises one of the shearing surfaces, and wherein the method comprises rotating the shearing member at an angular velocity of 500-850 rpm.

The method may further comprise applying the aerosol forming material and the active substance to the initial material prior to or while subjecting the initial material to the increased mechanical pressure.

The method may further comprise applying the aerosol forming material and the active substance to the aerosol-generating material after subjecting the initial material to the increased mechanical pressure.

The method may further comprise applying the aerosol forming material and the binder to the initial material prior to or while subjecting the initial material to the increased mechanical pressure.

The method may further comprise applying the aerosol forming material and the binder to the aerosol-generating material after subjecting the initial material to the increased mechanical pressure.

SUBSTITUTE SHEET (RULE 26) The method may further comprise applying the active substance and the binder to the initial material prior to or while subjecting the initial material to the increased mechanical pressure. The method may further comprise applying the active substance and the binder to the aerosol-generating material after subjecting the initial material to the increased mechanical pressure.

The method may further comprise applying the aerosol forming material, the active substance, and the binder to the initial material prior to or while subjecting the initial material to the increased mechanical pressure.

The method may further comprise applying the aerosol forming material, the active substance, and the binder to the aerosol-generating material after subjecting the initial material to the increased mechanical pressure.

According to a third aspect of the present disclosure, there is provided a method of manufacturing aerosol generating material, the method comprising: providing pre-sized particulate botanical material, wherein the botanical material contains less than 95%, by mass, of tobacco material; providing pre-sized cellulose fibre; combining the botanical material with the cellulose fibre to provide an initial material comprising at least 50%, by mass, of the botanical material; and, processing the initial material by: setting the initial material to a predefined moisture content; subjecting the initial material to an increase in temperature; and subjecting the initial material an increased pressure in order to bind the botanical material to the cellulose fibre to thereby produce the aerosol generating material.

Thus, the method may be a method of manufacturing non-continuous aerosol generating material.

SUBSTITUTE SHEET (RULE 26) The botanical material may contain less than 60%, by mass, of tobacco material, such as less than 55%, 50%, 45%, 40%, 35%, 30%, or less than 25% by mass, of tobacco material. The botanical material may contain less than 20%, or less than 15%, such as less than 10%, by mass, of tobacco material.

The botanical material may contain less than 1%, by mass, of tobacco material, or may contain no tobacco material.

The botanical material maybe a non-tobacco botanical material. The aerosol generating material may contain no tobacco material.

The botanical material may comprise more than 30%, by mass, of non-tobacco botanical material, such as more than 40%, more than 50%, more than 60%, more than 70%, more than 80%, more than 90%, or more than 95% non-tobacco botanical material.

The botanical material may comprise or consist of mint, eucalyptus, lavender, ginger, cinnamon, rooibos, and/or clove material.

The initial material, and/or the aerosol generating material, may comprise at least 5%, by mass, of cellulose fibre. The initial material may comprise 5-20%, by mass, of cellulose fibre.

The cellulose fibre may be a non-tobacco cellulose fibre. The cellulose fibre may comprise or consist of wood pulp.

The initial material, and/or the aerosol generating material, may comprise 60-75%, by mass, of botanical material.

The initial material, and/or the aerosol generating material, may comprise an aerosol forming material. The aerosol forming material maybe present in an amount of 5-30% by mass, such as 10-25%, or 15-20%, by mass.

SUBSTITUTE SHEET (RULE 26) The aerosol forming material may comprise glycerol, propylene glycol, or a mixture of glycerol and propylene glycol.

The aerosol generating material may have a Dpgo value of between 1.2mm and 6.0mm, a Dp5O value of between 1.1mm and 2.4mm and a Dpio value of between 0.2mm and

1.5mm.

The pre-sized cellulose fibre may have a Dpgo value of between 130 micrometres and 200 micrometres, a Dpso value of between 50 micrometres and 100 micrometres, and a Dpio value of between 10 micrometres and 50 micrometres.

The pre-sized botanical material and the pre-sized cellulose fibre may have particle size distributions that substantially overlap or correspond in size. The initial material, and/or the aerosol generating material, may further comprise a binder. The binder maybe present in an amount of up to 15%, 20%, or 25% by mass.

The binder may comprise carboxymethyl cellulose (CMC), starch, guar gum, xanthan gum, acacia gum and/or hydroxypropyl cellulose (HPC).

Processing the initial material may comprise conveying the initial material through a conveyor which builds up a mechanical pressure, wherein the conveyer is operated at a throughput of 25-75 kg/hr. Processing the initial material may comprise the use of a water flow rate of less than 12 L/h.

SUBSTITUTE SHEET (RULE 26) The initial material, and/or the aerosol generating material, may comprise nicotine or a nicotine salt. The nicotine salt may be selected from nicotine benzoate, nicotine levulinate, nicotine citrate, nicotine lactate, or combinations thereof. The nicotine may be present in an amount of up to 3%, such as about 0.5%, 1%, or 2%, by weight of the initial material and/ or resulting aerosol-generating material.

The initial material, and/or the aerosol generating material, may comprise an acid. The total amount of the acid may be from about 0.1% to about 5% by weight of the initial material and/or resulting aerosol-generating material. The acid maybe selected from the group consisting of lactic acid, benzoic acid, citric acid, levulinic acid, 2- methylbutyric acid, and 2-methylvaleric acid. In some embodiments, the acid is lactic acid.

According to a fourth aspect of the present disclosure, there is provided an aerosol generating material, comprising: at least 20%, by mass, of particulate botanical material; non-tobacco cellulose fibre; and at least one additive selected from: an aerosol forming material; an active substance; and a binder.

The particulate botanical material may comprise particulate tobacco material, or particulate non-tobacco material, or a combination thereof.

The particulate botanical material may comprise particulate tobacco material, or particulate non-tobacco botanical material, or a combination thereof.

According to a fifth aspect of the present disclosure, there is provided an aerosol generating material produced, obtained, or obtainable by the method of any one or more of the first, second, and/or third aspects. The aerosol generating material may have a filling power (also referred to as ‘filling value’ or ‘fill value’) of greater than 25 cm3/iog, such as greater than 30 cm3/iog. The

SUBSTITUTE SHEET (RULE 26) aerosol generating material may have a filling power of 25-50 citf/ 10g, such as 27-48 cm3/ 10g, or 29-45 cm3/ 10g. The aerosol generating material may have a filling power of greater than 25 cm3/iog, 30 cm3/iog, 35 cm3/iog, or 40 cm3/iog. The aerosol generating material may have a filling power of less than 65 cm3/iog, 60 cm3/iog, 58 cm3/iog, or 55 cm3/iog.

The aerosol generating material has a high filling value and low density. As a result, the aerosol generating material advantageously may comprise a high level of aerosol forming material, for example, of up to 40% by mass. In some embodiments, the aerosol generating material may comprise aerosol forming material in an amount of 10- 30%.

According to a sixth aspect of the present disclosure, there is provided a component for a delivery system, wherein the component comprises aerosol generating material of the fourth and/ or fifth aspect, or produced, obtained, or obtainable by the method of any one or more of the first, second, and/ or third aspects.

The component may be for an aerosol provision system. According to a seventh aspect of the present disclosure, there is provided a product comprising a component according to the sixth aspect.

The product may be a non-combustible aerosol provision system. The non-combustible aerosol provision system may be an aerosol generating material heating system, also known as a heat-not-burn system. The non-combustible aerosol provision system may be a tobacco heating system.

According to an eighth aspect of the present disclosure, there is provided an article for use in or as an aerosol provision system, the article comprising a component according to the sixth aspect.

According to a ninth aspect of the present disclosure, there is provided an article comprising an aerosol generating material produced in accordance with the method of any one or more of the first, second, and/or third aspects.

SUBSTITUTE SHEET (RULE 26) According to a tenth aspect of the present disclosure, there is provided the use of an aerosol-generating material of the fourth or fifth aspect in an article for use in an aerosol provision system. According to an eleventh aspect of the present disclosure, there is provided an article for use in or as an aerosol provision system comprising an aerosol-generating material of the fourth or fifth aspect.

According to a twelfth aspect of the present disclosure, there is provided a system comprising an aerosol-generating material of the fourth or fifth aspect and a device arranged to heat the aerosol-generating material and generate an aerosol from the aerosol-generating material.

Pre-sized botanical material “Pre-sized” material refers to material that has been subjected to a pre-sizing step prior to combining the material with other material to form the initial material.

As used herein, the term “botanical material” includes any material derived from any plant part including, but not limited to, leaves, bark, buds, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, and/or shells.

The botanical material is preferably an aromatic botanical material. “Aromatic” refers to any material having a distinctive, fragrant smell. Thus, an aromatic botanical material is any botanical material that is capable of being identified by its aroma. The botanical material may comprise or consist of one or a combination of botanical materials derived or obtained from: eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof.

SUBSTITUTE SHEET (RULE 26) The botanical material may comprise or consist of mint, eucalyptus, lavender, ginger, cinnamon, rooibos, and/or clove material. The botanical material may comprise or consist of mint, eucalyptus, lavender, ginger, cinnamon, and/or clove material.

The botanical material may comprise or consist of mint, eucalyptus, lavender, ginger, and/ or cinnamon material.

The botanical material may comprise or consist of mint, eucalyptus, lavender, ginger, rooibos, and/or cinnamon material.

The botanical material may comprise or consist of mint, eucalyptus, lavender, and/or cinnamon material.

The botanical material may comprise or consist of mint material.

The botanical material may comprise or consist of eucalyptus material.

The botanical material may comprise or consist of lavender material.

The botanical material may comprise or consist of clove material. The botanical material may comprise or consist of ginger material.

The botanical material may comprise or consist of rooibos material.

The botanical material maybe a non-tobacco botanical material, and preferably includes or contains no tobacco material.

The initial material may comprise between 50% and 95%, such as between 52% and 90%, between 55% and 85%, or between 57% and 80%, by mass, of botanical material. Preferably, the initial material may comprise between 60% and 75%, such as 62-73%, by mass, of botanical material.

SUBSTITUTE SHEET (RULE 26) In embodiments in which the initial material and/or aerosol generating material comprises less than 10% aerosol forming material, the initial material may comprise between 60% and 95%, such as between 65% and 90%, between 67% and 87%, between 70% and 85%, or between 72% and 82% by mass, of botanical material.

The botanical material maybe pre-sized to the required particle size range by any suitable method or combination of methods. Suitable methods may include a sizereduction method such as an appropriate milling method, and/or a size-selection method, such as an appropriate sieving and/or sorting method.

The botanical material maybe conditioned, such as dried, to provide a predetermined moisture content. Conditioning may be conducted prior to and/ or after any size reduction and/or selection process.

The botanical material may have a moisture content, or may be conditioned to have a moisture content, greater than 2%, greater than 3%, greater than 4%, or greater than 5%- The botanical material may have a moisture content, or may be conditioned to have a moisture content, less than 30%, less than 28%, or less than 25%.

The pre-sized botanical material may have a smaller particle size than the pre-sized cellulose fibre, for example, based on the average (modal, median, or mean) particle size. In the disclosed process, pre-sized botanical material is bound to pre-sized cellulose fibre by the application of increased temperature and pressure to form a aerosol generating material.

In some embodiments, the pre-sized botanical material may have a particle size distribution that substantially overlaps or corresponds in size with that of the pre-sized cellulose fibre. The use of botanical material and cellulose fibre material of similar and/or overlapping particle size distribution improves mixing to produce a more homogenous mixture, resulting in the manufacture of material that is more repeatable and consistent.

SUBSTITUTE SHEET (RULE 26) In some embodiments, the pre-sized botanical material may have a larger particle size than the pre-sized cellulose fibre, for example, based on the average (modal, median, or mean) particle size. The Dp9O, Dp5O, and Dpio values refer to the particle size value that 90%, 50%, and 10%, respectively, of the material, by mass, is smaller than. For instance, if the Dpgo value is imm then 90% (by mass) of the material, such as the pre-sized botanical material or aerosol generating material (as indicated), has a particle size smaller than imm.

In some embodiments, the botanical material may be used in particulate form. In embodiments in which the botanical material is in particulate form, the pre-sized botanical material may have a Dpgo value of greater than 3mm, a Dpso value of greater than 1.5mm, and/or a Dpio value of between 0.2mm and 0.8mm, such as between 0.3mm and 0.6mm, or about 0.4mm. Botanical materials that may advantageously be used in particulate form include, for example, botanical material that consists of or comprises clove or lavender material.

In some embodiments, the botanical material may be used in powdered form. In embodiments in which the botanical material is in powdered form, the pre-sized botanical material may have a Dpgo value of between 0.2mm and 1.5mm, such as between 0.35mm and 1.15mm, a Dpso value of between 0.1mm and 0.8mm, such as between 0.15mm and 0.7mm, and/or a Dpio value of 0.01mm and 0.5mm, such as between 0.03mm and 0.25mm. Botanical materials that may advantageously be used in powdered form include, for example, milled botanical material that consists of or comprises mint, eucalyptus, cinnamon, and/or lavender material.

In some embodiments, the botanical material may comprise a combination of materials in particulate and powdered form. The use of a combination of particulate and powdered botanical material has been found to improve the characteristics of the aerosol-generating material in comparison to formulations containing just powdered material.

In some embodiments, lavender botanical material may comprise a combination of materials in particulate and powdered form. In such embodiments, the lavender botanical material may comprise a combination of lavender flower particulate material

SUBSTITUTE SHEET (RULE 26) and lavender powder. The ratio of lavender powder: lavender flower material maybe about 58:15 (w/w).

In some embodiments, clove botanical material may comprise clove bud material. Clove botanical material may comprise a combination of materials in particulate and powdered form. In such embodiments, the clove botanical material may comprise a combination of clove bud particulate material and clove powder. The ratio of clove powder: clove bud material maybe about 51.5:14.5 (w/w). The use of pre-sized botanical material having larger particle sizes may be advantageous in some embodiments. For example, the use of larger particles has been found to provide manufacturing advantages. In particular, for botanical material having a small particle size, such as material in powdered form, a low feeding rate is preferably used to reduce the risk of clogging the system. In such embodiments, the use of larger particles, such as material in particulate form, is advantageous because it allows the use of a higher feeding rate, providing manufacturing efficiencies.

The use of pre-sized botanical material having smaller particle sizes may be advantageous in some embodiments. For example, in some embodiments, it has been found that there is an inverse proportional relationship between particle size and filling density, such that the use of botanical material having a smaller particle size may provide an aerosol generating material having a greater filling value.

Botanical material having a particle size of less than 1 mm is referred to as “botanical fines” material. Botanical fines material may comprise, consist of, or consist essentially of, dust from the processing of botanical material, which may include the production of any products containing botanical material. Thus, an advantage of the disclosed process is that botanical material that would otherwise be considered waste material may be productively used in the production of the disclosed aerosol generating material.

Volatile aroma and flavour compounds have surprisingly been found to be retained in the aerosol generating material in amounts that have not previously been possible, in particular in relation to the disclosed botanical material, providing flavour and sensory profiles, that have not previously been possible in aerosol generating materials.

Mint botanical material

SUBSTITUTE SHEET (RULE 26) The botanical material maybe a mint botanical material. The mint botanical material may comprise or consist of material derived from a mint plant.

‘Mint’, ‘mint material’, and ‘mint botanical material’ refers to any material derived from a plant from the genus Mentha in the family Lamiaceae. Any plant from this genus may be referred to as a ‘mint plant’. The mint botanical material may comprise or consist of material 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, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens. The mint botanical material may comprise material from any part of a mint plant, and preferably, the mint botanical material may comprise or consist of mint leaf and/or mint stem material. The mint botanical material may comprise menthol. The mint plant 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 longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens. The pre-sized particulate mint botanical material may comprise material from any part of a mint plant, such as mint leaf and/or mint stem material. Preferably, the pre-sized particulate mint botanical material may comprise mint leaf and/or mint stem material.

The pre-sized particulate mint botanical material may have a moisture content, or may be conditioned to have a moisture content greater than 2%, greater than 3%, greater than 4%, or greater than 5%.

The pre-sized particulate mint botanical material may have a moisture content, or may be conditioned to have a moisture content less than 10%, less than 8%, less than 7%, or less than 6%.

The pre-sized particulate mint botanical material may comprise greater than 0.1%, greater than 0.2%, or greater than 0.3%, by mass, of material having a particle size of greater than 0.85mm. The pre-sized particulate mint botanical material may comprise less than 5%, less than 3%, or less than 1%, by mass, of material having a particle size of greater than 0.85mm.

SUBSTITUTE SHEET (RULE 26) The pre-sized particulate mint botanical material may comprise greater than 90%, greater than 95%, greater than 99%, or greater than 99.5%, by mass, of material having a particle size of less than 0.85mm. The pre-sized particulate mint botanical material may comprise less than 99.995%, less than 99.95%, less than 99.9%, or less than 99.8%, by mass, of material having a particle size of less than 0.85mm.

The pre-sized particulate mint botanical material may comprise greater than 0.1%, greater than 0.5%, greater than 1%, or greater than 1.5%, by mass, of mint botanical material having a particle size of greater than 0.5mm. The pre-sized particulate mint botanical material may comprise less than 10%, less than 5%, less than 3%, or less than 2%, by mass, of mint botanical material having a particle size of greater than 0.5mm.

The pre-sized particulate mint botanical material may comprise greater than 95%, greater than 96%, greater than 97%, or greater than 98%, by mass, of mint fines material, having a particle size of less than 0.5mm. The pre-sized particulate mint botanical material may comprise less than 99.95%, less than 99.5%, less than 99%, or less than 98.5%, by mass, of mint fines material, having a particle size of less than 0.5mm.

The pre-sized particulate mint botanical material may comprise greater than 1%, greater than 3%, greater than 5%, or greater than 8%, by mass, of mint botanical material having a particle size of greater than 355 micrometres. The pre-sized particulate mint botanical material may comprise less than 20%, less than 15%, less than 12%, or less than 10%, by mass, of mint botanical material having a particle size of greater than 355 micrometres.

The pre-sized particulate mint botanical material may comprise greater than 75%, greater than 80%, greater than 85%, or greater than 90%, by mass, of mint fines material, having a particle size of less than 355 micrometres. The pre-sized particulate mint botanical material may comprise less than 99%, less than 97%, less than 95%, or less than 92%, by mass, of mint fines material, having a particle size of less than 355 micrometres. The pre-sized particulate mint botanical material may comprise greater than 5%, greater than 10%, greater than 15%, or greater than 20%, by mass, of mint botanical

SUBSTITUTE SHEET (RULE 26) material having a particle size of greater than 250 micrometres. The pre-sized particulate mint botanical material may comprise less than 35%, less than 30%, less than 25%, or less than 23%, by mass, of mint botanical material having a particle size of greater than 250 micrometres.

The pre-sized particulate mint botanical material may comprise greater than 50%, greater than 60%, greater than 70%, or greater than 75%, by mass, of mint fines material, having a particle size of less than 250 micrometres. The pre-sized particulate mint botanical material may comprise less than 95%, less than 90%, less than 85%, or less than 80%, by mass, of mint fines material, having a particle size of less than 250 micrometres.

The pre-sized particulate mint botanical material may comprise greater than 40%, greater than 50%, greater than 55%, or greater than 60%, by mass, of mint botanical material having a particle size of greater than too micrometres. The pre-sized particulate mint botanical material may comprise less than 80%, less than 70%, less than 65%, or less than 62%, by mass, of mint botanical material having a particle size of greater than too micrometres. The pre-sized particulate mint botanical material may comprise greater than 20%, greater than 25%, greater than 30%, or greater than 35%, by mass, of mint fines material, having a particle size of less than too micrometres. The pre-sized particulate mint botanical material may comprise less than 60%, less than 50%, less than 45%, or less than 40%, by mass, of mint fines material, having a particle size of less than too micrometres.

The mint fines material may comprise, consist of, or consist essentially of, dust from the processing of mint plant material, which may include the production of any products containing mint material.

The pre-sized particulate mint botanical material may have a Dpgo value of between 0.1mm and 0.6mm, such as between 0.3mm and 0.4mm. The pre-sized particulate mint botanical material may have a Dpgo particle size of about 0.35mm.

SUBSTITUTE SHEET (RULE 26) The pre-sized particulate mint botanical material may have a Dpso value of between 0.05mm and 0.4mm, such as between 0.1mm and 0.2mm. The pre-sized particulate mint botanical material may have a Dpso particle size of about 0.15mm. The pre-sized particulate mint botanical material may have a Dpio value of between 0.01mm and 0.1mm, such as between 0.02mm and 0.06mm. The pre-sized particulate mint botanical material may have a Dpio particle size of about 0.03mm.

Eucalyptus botanical material The botanical material may be a eucalyptus botanical material. The eucalyptus botanical material may comprise or consist of material derived from a eucalyptus plant.

‘Eucalyptus’, ‘eucalyptus material’, and ‘eucalyptus botanical material’ refers to any material derived from a plant from the genus Eucalyptus, which contains various species of flowering trees, shrubs or mallees in the myrtle family, Myrtaceae. Any plant or tree from this genus maybe referred to as a ‘eucalyptus plant’ or ‘eucalyptus tree’. The eucalyptus botanical material may comprise material from any part of a eucalyptus tree, and preferably, the eucalyptus botanical material may comprise or consist of eucalyptus leaf and/or eucalyptus stem and/or eucalyptus flower material. The eucalyptus botanical material may comprise cineole.

The pre-sized particulate eucalyptus botanical material may comprise material from any part of a eucalyptus plant. Preferably, the pre-sized particulate eucalyptus botanical material may comprise eucalyptus leaf material.

The pre-sized particulate eucalyptus botanical material may have a moisture content, or may be conditioned to have a moisture content greater than 5%, greater than 7%, greater than 9%, or greater than 10%. The pre-sized particulate eucalyptus botanical material may have a moisture content, or may be conditioned to have a moisture content less than 18%, less than 15%, less than 12%, or less than 11%.

The pre-sized particulate eucalyptus botanical material may comprise greater than 20%, greater than 30%, or greater than 35%, by mass, of material having a particle size of greater than 0.85mm. The pre-sized particulate eucalyptus botanical material may

SUBSTITUTE SHEET (RULE 26) comprise less than 50%,, less than 45%, less than 40%, or less than 37%, by mass, of material having a particle size of greater than 0.85mm.

The pre-sized particulate eucalyptus botanical material may comprise greater than 50%, greater than 55%, greater than 60%, or greater than 63%, by mass, of material having a particle size of less than 0.85mm. The pre-sized particulate eucalyptus botanical material may comprise less than 80%, less than 70%, less than 65%, or less than 64%, by mass, of material having a particle size of less than 0.85mm. The pre-sized particulate eucalyptus botanical material may comprise greater than 50%, greater than 60%, greater than 63%, or greater than 66%, by mass, of eucalyptus botanical material having a particle size of greater than 0.5mm. The pre-sized particulate eucalyptus botanical material may comprise less than 80%, less than 75%, less than 70%, or less than 67%, by mass, of eucalyptus botanical material having a particle size of greater than 0.5mm.

The pre-sized particulate eucalyptus botanical material may comprise greater than 20%, greater than 25%, greater than 30%, or greater than 33%, by mass, of eucalyptus fines material, having a particle size of less than 0.5mm. The pre-sized particulate eucalyptus botanical material may comprise less than 50%, less than 40%, less than 37%, or less than 34%, by mass, of eucalyptus fines material, having a particle size of less than 0.5mm.

The pre-sized particulate eucalyptus botanical material may comprise greater than 60%, greater than 70%, greater than 75%, or greater than 78%, by mass, of eucalyptus botanical material having a particle size of greater than 355 micrometres. The pre-sized particulate eucalyptus botanical material may comprise less than 95%, less than 90%, less than 85%, or less than 80%, by mass, of eucalyptus botanical material having a particle size of greater than 355 micrometres.

The pre-sized particulate eucalyptus botanical material may comprise greater than 5%, greater than 10%, greater than 15%, or greater than 20%, by mass, of eucalyptus fines material, having a particle size of less than 355 micrometres. The pre-sized particulate eucalyptus botanical material may comprise less than 40%, less than 30%, less than 25%, or less than 22%, by mass, of eucalyptus fines material, having a particle size of less than 355 micrometres.

SUBSTITUTE SHEET (RULE 26) The pre-sized particulate eucalyptus botanical material may comprise greater than 70%, greater than 80%, greater than 85%, or greater than 87%, by mass, of eucalyptus botanical material having a particle size of greater than 250 micrometres. The pre-sized particulate eucalyptus botanical material may comprise less than 97%, less than 95%, less than 90%, or less than 88%, by mass, of eucalyptus botanical material having a particle size of greater than 250 micrometres.

The pre-sized particulate eucalyptus botanical material may comprise greater than 5%, greater than 7%, greater than 10%, or greater than 12%, by mass, of eucalyptus fines material, having a particle size of less than 250 micrometres. The pre-sized particulate eucalyptus botanical material may comprise less than 30%, less than 20%, less than 15%, or less than 13%, by mass, of eucalyptus fines material, having a particle size of less than 250 micrometres.

The pre-sized particulate eucalyptus botanical material may comprise greater than 80%, greater than 90%, greater than 93%, or greater than 96%, by mass, of eucalyptus botanical material having a particle size of greater than 100 micrometres. The pre-sized particulate eucalyptus botanical material may comprise less than 99.5%, less than 99%, less than 98%, or less than 97%, by mass, of eucalyptus botanical material having a particle size of greater than 100 micrometres.

The pre-sized particulate eucalyptus botanical material may comprise greater than 0.5%, greater than 1%, greater than 2%, or greater than 3%, by mass, of eucalyptus fines material, having a particle size of less than 100 micrometres. The pre-sized particulate eucalyptus botanical material may comprise less than 15%, less than 10%, less than 7%, or less than 4%, by mass, of eucalyptus fines material, having a particle size of less than 100 micrometres. The eucalyptus botanical material may comprise, consist of, or consist essentially of, dust from the processing of eucalyptus plant material, which may include the production of any products containing eucalyptus material.

The pre-sized particulate eucalyptus botanical material may have a Dpgo value of between 0.8mm and 1.5mm, such as between imm and 1.3mm. The pre-sized

SUBSTITUTE SHEET (RULE 26) particulate eucalyptus botanical material may have a Dpgo particle size of about 1.15mm.

The pre-sized particulate eucalyptus botanical material may have a Dpso value of between 0.4mm and imm, such as between 0.6mm and 0.8mm. The pre-sized particulate eucalyptus botanical material may have a Dpso particle size of about 0.7mm.

The pre-sized particulate eucalyptus botanical material may have a Dpio value of between 0.05mm and 0.5mm, such as between 0.1mm and 0.3mm. The pre-sized particulate eucalyptus botanical material may have a Dpio particle size of about 0.2mm.

Lavender botanical material The botanical material may be a lavender botanical material. The lavender botanical material may comprise or consist of material derived from a lavender plant.

‘Lavender’, ‘lavender material’, and ‘lavender botanical material’ refers to any material derived from a plant from the genus Lavandula in the family Lamiaceae. Any plant from this genus may be referred to as a ‘lavender plant’. The lavender botanical material may comprise material from any part of a lavender plant, and preferably, the lavender botanical material may comprise or consist of lavender flower and/or lavender bud material. The lavender botanical material may comprise, for example, limonene, linalool, linalyl acetate, and/or camphor.

The pre-sized particulate lavender botanical material may comprise material from any part of a lavender plant. Preferably, the pre-sized particulate lavender botanical material may comprise lavender flower and/or lavender stem material. The pre-sized particulate lavender botanical material may have a moisture content, or may be conditioned to have a moisture content greater than 8%, greater than 10%, greater than 12%, or greater than 13%.

The pre-sized particulate lavender botanical material may have a moisture content, or may be conditioned to have a moisture content less than 20%, less than 17%, less than

15%, or less than 14%.

SUBSTITUTE SHEET (RULE 26) The pre-sized particulate lavender botanical material may comprise greater than 20%, greater than 25%, or greater than 30%, by mass, of material having a particle size of greater than 0.85mm. The pre-sized particulate lavender botanical material may comprise less than 40%, less than 35%, or less than 31%, by mass, of material having a particle size of greater than 0.85mm.

The pre-sized particulate lavender botanical material may comprise greater than 50%, greater than 60%, greater than 65%, or greater than 69%, by mass, of material having a particle size of less than 0.85mm. The pre-sized particulate lavender botanical material may comprise less than 90%, less than 80%, less than 75%, or less than 70%, by mass, of material having a particle size of less than 0.85mm.

The pre-sized particulate lavender botanical material may comprise greater than 50%, greater than 55%, greater than 60%, or greater than 65%, by mass, of lavender botanical material having a particle size of greater than 0.5mm. The pre-sized particulate lavender botanical material may comprise less than 80%, less than 75%, less than 70%, or less than 66%, by mass, of lavender botanical material having a particle size of greater than 0.5mm.

The pre-sized particulate lavender botanical material may comprise greater than 20%, greater than 25%, greater than 30%, or greater than 34%, by mass, of lavender fines material, having a particle size of less than 0.5mm. The pre-sized particulate lavender botanical material may comprise less than 50%, less than 45%, less than 40%, or less than 35%, by mass, of lavender fines material, having a particle size of less than 0.5mm.

The pre-sized particulate lavender botanical material may comprise greater than 60%, greater than 70%, greater than 75%, or greater than 78%, by mass, of lavender botanical material having a particle size of greater than 355 micrometres. The pre-sized particulate lavender botanical material may comprise less than 90%, less than 85%, less than 83%, or less than 79%, by mass, of lavender botanical material having a particle size of greater than 355 micrometres.

The pre-sized particulate lavender botanical material may comprise greater than 10%, greater than 15%, greater than 18%, or greater than 21%, by mass, of lavender fines material, having a particle size of less than 355 micrometres. The pre-sized particulate

SUBSTITUTE SHEET (RULE 26) lavender botanical material may comprise less than 40%, less than 30%, less than 25%, or less than 22%, by mass, of lavender fines material, having a particle size of less than 355 micrometres. The pre-sized particulate lavender botanical material may comprise greater than 70%, greater than 80%, greater than 85%, or greater than 88%, by mass, of lavender botanical material having a particle size of greater than 250 micrometres. The pre-sized particulate lavender botanical material may comprise less than 98%, less than 95%, less than 92%, or less than 89%, by mass, of lavender botanical material having a particle size of greater than 250 micrometres.

The pre-sized particulate lavender botanical material may comprise greater than 2%, greater than 5%, greater than 8%, or greater than 11%, by mass, of lavender fines material, having a particle size of less than 250 micrometres. The pre-sized particulate lavender botanical material may comprise less than 30%, less than 20%, less than 15%, or less than 12%, by mass, of lavender fines material, having a particle size of less than 250 micrometres.

The pre-sized particulate lavender botanical material may comprise greater than 80%, greater than 90%, greater than 95%, or greater than 98%, by mass, of lavender botanical material having a particle size of greater than too micrometres. The pre-sized particulate lavender botanical material may comprise less than 99.95%, less than 99.5%, less than 99%, or less than 98.5%, by mass, of lavender botanical material having a particle size of greater than too micrometres.

The pre-sized particulate lavender botanical material may comprise greater than 0.1%, greater than 0.5%, greater than 1%, or greater than 1.5%, by mass, of lavender fines material, having a particle size of less than too micrometres. The pre-sized particulate lavender botanical material may comprise less than 10%, less than 5%, less than 2%, or less than 1.7%, by mass, of lavender fines material, having a particle size of less than too micrometres.

The lavender botanical material may comprise, consist of, or consist essentially of, dust from the processing of lavender plant material, which may include the production of any products containing lavender material.

SUBSTITUTE SHEET (RULE 26) The pre-sized particulate lavender botanical material may have a Dpgo value of between 0.7mm and 1.5mm, such as between 0.9mm and 1.2mm. The pre-sized particulate lavender botanical material may have a Dpgo particle size of about 1.05mm. The pre-sized particulate lavender botanical material may have a Dpso value of between 0.3mm and imm, such as between 0.5mm and 0.8mm. The pre-sized particulate lavender botanical material may have a Dpso particle size of about 0.65mm.

The pre-sized particulate lavender botanical material may have a Dpio value of between 0.1mm and 0.5mm, such as between 0.2mm and 0.3mm. The pre-sized particulate lavender botanical material may have a Dpio particle size of about 0.25mm.

Cinnamon botanical material

The botanical material maybe a cinnamon botanical material. The cinnamon botanical material may comprise or consist of material derived from cinnamon.

‘Cinnamon’, ‘cinnamon material’, and ‘cinnamon botanical material’ refers to any material derived from a plant from the genus Cinnamomum in the family Lauraceae. Cinnamon is a spice obtained from the inner bark of various tree species from this genus, and any tree from this genus may be referred to as a ‘cinnamon plant’ or

‘cinnamon tree’. The cinnamon botanical material may comprise material from any part of a cinnamon plant, and preferably, the cinnamon botanical material may comprise or consist of cinnamon bark material. The cinnamon botanical material may comprise, for example cinnamaldehyde, trans-cinnamaldehyde (cin), procyanidins, and/or catechins.

The pre-sized particulate cinnamon botanical material may comprise material from any part of a cinnamon plant. Preferably, the pre-sized particulate cinnamon botanical material may comprise cinnamon bark material. The pre-sized particulate cinnamon botanical material may have a moisture content, or may be conditioned to have a moisture content greater than 8%, greater than 10%, greater than 12%, or greater than 14%.

The pre-sized particulate cinnamon botanical material may have a moisture content, or may be conditioned to have a moisture content less than 20%, less than 18%, less than 16%, or less than 15%.

SUBSTITUTE SHEET (RULE 26) The pre-sized particulate cinnamon botanical material may comprise greater than 20%, greater than 30%, or greater than 34%, by mass, of material having a particle size of greater than 0.85mm. The pre-sized particulate cinnamon botanical material may comprise less than 50%, less than 40%, or less than 35%, by mass, of material having a particle size of greater than 0.85mm.

The pre-sized particulate cinnamon botanical material may comprise greater than 50%, greater than 55%, greater than 60%, or greater than 65%, by mass, of material having a particle size of less than 0.85mm. The pre-sized particulate cinnamon botanical material may comprise less than 80%, less than 75%, less than 70%, or less than 66%, by mass, of material having a particle size of less than 0.85mm.

The pre-sized particulate cinnamon botanical material may comprise greater than 50%, greater than 55%, greater than 60%, or greater than 63%, by mass, of cinnamon botanical material having a particle size of greater than 0.5mm. The pre-sized particulate cinnamon botanical material may comprise less than 80%, less than 70%, less than 67%, or less than 64%, by mass, of cinnamon botanical material having a particle size of greater than 0.5mm.

The pre-sized particulate cinnamon botanical material may comprise greater than 20%, greater than 30%, greater than 33%, or greater than 36%, by mass, of cinnamon fines material, having a particle size of less than 0.5mm. The pre-sized particulate cinnamon botanical material may comprise less than 50%, less than 45%, less than 40%, or less than 37%, by mass, of cinnamon fines material, having a particle size of less than 0.5mm.

The pre-sized particulate cinnamon botanical material may comprise greater than 50%, greater than 60%, greater than 70%, or greater than 74%, by mass, of cinnamon botanical material having a particle size of greater than 355 micrometres. The pre-sized particulate cinnamon botanical material may comprise less than 90%, less than 85%, less than 80%, or less than 75%, by mass, of cinnamon botanical material having a particle size of greater than 355 micrometres. The pre-sized particulate cinnamon botanical material may comprise greater than 10%, greater than 15%, greater than 20%, or greater than 25%, by mass, of cinnamon fines

SUBSTITUTE SHEET (RULE 26) material, having a particle size of less than 355 micrometres. The pre-sized particulate cinnamon botanical material may comprise less than 40%, less than 35%, less than 30%, or less than 26%, by mass, of cinnamon fines material, having a particle size of less than 355 micrometres.

The pre-sized particulate cinnamon botanical material may comprise greater than 70%, greater than 75%, greater than 80%, or greater than 83%, by mass, of cinnamon botanical material having a particle size of greater than 250 micrometres. The pre-sized particulate cinnamon botanical material may comprise less than 95%, less than 90%, less than 87%, or less than 84%, by mass, of cinnamon botanical material having a particle size of greater than 250 micrometres.

The pre-sized particulate cinnamon botanical material may comprise greater than 5%, greater than 10%, greater than 13%, or greater than 16%, by mass, of cinnamon fines material, having a particle size of less than 250 micrometres. The pre-sized particulate cinnamon botanical material may comprise less than 30%, less than 25%, less than 20%, or less than 17%, by mass, of cinnamon fines material, having a particle size of less than 250 micrometres. The pre-sized particulate cinnamon botanical material may comprise greater than 80%, greater than 85%, greater than 90%, or greater than 94%, by mass, of cinnamon botanical material having a particle size of greater than too micrometres. The pre-sized particulate cinnamon botanical material may comprise less than 99.5%, less than 99%, less than 97%, or less than 95%, by mass, of cinnamon botanical material having a particle size of greater than too micrometres.

The pre-sized particulate cinnamon botanical material may comprise greater than 0.5%, greater than 1%, greater than 3%, or greater than 5%, by mass, of cinnamon fines material, having a particle size of less than 100 micrometres. The pre-sized particulate cinnamon botanical material may comprise less than 20%, less than 15%, less than 10%, or less than 6%, by mass, of cinnamon fines material, having a particle size of less than too micrometres.

The cinnamon botanical material may comprise, consist of, or consist essentially of, dust from the processing of cinnamon plant material, which may include the production of any products containing cinnamon material.

SUBSTITUTE SHEET (RULE 26) The pre-sized particulate cinnamon botanical material may have a Dpgo value of between o.8mm and 1.5mm, such as between 1.0mm and 1.3mm. The pre-sized particulate cinnamon botanical material may have a Dpgo particle size of about 1.15mm.

The pre-sized particulate cinnamon botanical material may have a Dpso value of between 0.4mm and imm, such as between 0.6mm and 0.8mm. The pre-sized particulate cinnamon botanical material may have a Dpso particle size of about 0.65mm.

The pre-sized particulate cinnamon botanical material may have a Dpio value of between 0.05mm and 0.5mm, such as between 0.1mm and 0.3mm. The pre-sized particulate cinnamon botanical material may have a Dpio particle size of about 0.15 mm.

Clove botanical material

The botanical material maybe a clove botanical material. The clove material may comprise clove bud material and references herein to clove material, and/or clove botanical material, may refer to material derived from clove bud.

‘Clove’, ‘clove material’, and ‘clove botanical material’ refers to any material derived from a plant from the species Syzygium aromaticum, which maybe referred to as a ‘clove plant’ or ‘clove tree’. Clove material for use in the disclosed process may be derived from the bud of the clove plant material. The clove material may include, but is not limited to, the following type of clove material: Jawa, Bali, Manado, and/or Manado second grade. The use of clove material may provide a distinctive flavour and sensorial experience for the end user. The clove material may provide sensory effects including aroma, spicy, numbing, crackling, and/or throat soothing features. The clove botanical material may comprise eugenol.

The pre-sized particulate clove botanical material may have a moisture content, or may be conditioned to have a moisture content greater than 15%, greater than 18%, greater than 21%, or greater than 23%.

SUBSTITUTE SHEET (RULE 26) The pre-sized particulate clove botanical material may have a moisture content, or may be conditioned to have a moisture content less than 30%, less than 28%, less than 26%, or less than 24%. The pre-sized particulate clove botanical material may comprise greater than 60%, greater than 70%, or greater than 75%, by mass, of material having a particle size of greater than 0.85mm. The pre-sized particulate clove botanical material may comprise less than 90%, less than 80%, or less than 76%, by mass, of material having a particle size of greater than 0.85mm.

The pre-sized particulate clove botanical material may comprise greater than 10%, greater than 15%, greater than 20%, or greater than 24%, by mass, of material having a particle size of less than 0.85mm. The pre-sized particulate clove botanical material may comprise less than 40%, less than 35%, less than 30%, or less than 25%, by mass, of material having a particle size of less than 0.85mm.

The pre-sized particulate clove botanical material may comprise greater than 75%, greater than 80%, greater than 83%, or greater than 86%, by mass, of clove botanical material having a particle size of greater than 0.5mm. The pre-sized particulate clove botanical material may comprise less than 95%, less than 92%, less than 90%, or less than 87%, by mass, of clove botanical material having a particle size of greater than 0.5mm.

The pre-sized particulate clove botanical material may comprise greater than 5%, greater than 7%, greater than 10%, or greater than 13%, by mass, of clove fines material, having a particle size of less than 0.5mm. The pre-sized particulate clove botanical material may comprise less than 30%, less than 20%, less than 17%, or less than 14%, by mass, of clove fines material, having a particle size of less than 0.5mm. The pre-sized particulate clove botanical material may comprise greater than 80%, greater than 85%, greater than 90%, or greater than 93%, by mass, of clove botanical material having a particle size of greater than 355 micrometres. The pre-sized particulate clove botanical material may comprise less than 99%, less than 97%, less than 95%, or less than 94%, by mass, of clove botanical material having a particle size of greater than 355 micrometres.

SUBSTITUTE SHEET (RULE 26) The pre-sized particulate clove botanical material may comprise greater than 1%, greater than 3%, greater than 5%, or greater than 6%, by mass, of clove fines material, having a particle size of less than 355 micrometres. The pre-sized particulate clove botanical material may comprise less than 20%, less than 15%, less than 10%, or less than 7%, by mass, of clove fines material, having a particle size of less than 355 micrometres.

The pre-sized particulate clove botanical material may comprise greater than 90%, greater than 95%, greater than 97%, or greater than 99%, by mass, of clove botanical material having a particle size of greater than 250 micrometres. The pre-sized particulate clove botanical material may comprise less than 99.95%, or less than 99.5%, by mass, of clove botanical material having a particle size of greater than 250 micrometres. The pre-sized particulate clove botanical material may comprise greater than 0.05%, greater than 0.1%, greater than 0.5%, or greater than 0.6%, by mass, of clove fines material, having a particle size of less than 250 micrometres. The pre-sized particulate clove botanical material may comprise less than 5%, less than 2%, less than 1%, or less than 0.7%, by mass, of clove fines material, having a particle size of less than 250 micrometres.

The pre-sized particulate clove botanical material may comprise greater than 95%, greater than 98%, greater than 99%, or greater than 99.9%, by mass, of clove botanical material having a particle size of greater than 100 micrometres. Substantially all of the pre-sized particulate clove botanical material, such as 100%, by mass, of clove botanical material may have a particle size of greater than 100 micrometres.

The pre-sized particulate clove botanical material may comprise less than 1%, less than 0.5%, or less than 0.1%, by mass, of clove fines material, having a particle size of less than 100 micrometres. Substantially none of the pre-sized particulate clove botanical material, such as 0%, by mass, of clove botanical material may have a particle size of less than 100 micrometres.

The clove botanical material may comprise, consist of, or consist essentially of, dust from the processing of clove bud material, which may include the production of any products containing clove material.

SUBSTITUTE SHEET (RULE 26) The pre-sized particulate clove botanical material may have a Dpgo value of greater than 2mm, greater than 2.5mm, or greater than 3mm. The pre-sized particulate clove botanical material may have a Dpso value of greater than imm, greater than 1.25mm, or greater than 1.5mm.

The pre-sized particulate clove botanical material may have a Dpio value of between 0.1mm and 0.8mm, such as between 0.3mm and 0.5mm. The pre-sized particulate clove botanical material may have a Dpio particle size of about 0.4mm.

Ginger botanical material

The botanical material maybe a ginger botanical material. The ginger botanical material may comprise or consist of material derived from ginger.

‘Ginger’, ‘ginger material’, and ‘ginger botanical material’ refers to any material derived from a plant from the genus Zingiber in the family Zingiberaceae. Any plant from this genus maybe referred to as a ‘ginger plant’. Preferably, the ginger plant is Zingiber officinale, which is a flowering plant whose rhizome, known as ginger root or ginger, is widely used as a spice. The ginger botanical material may comprise material from any part of a ginger plant, and preferably, the ginger botanical material may comprise or consist of ginger root/rhizome material. The ginger botanical material may comprise, for example, sesquiterpene hydrocarbons, gingerol, shogaol, and/or oleoresin. The pre-sized particulate ginger botanical material may comprise material from any part of a ginger plant. Preferably, the pre-sized particulate ginger botanical material may comprise ginger root material.

The ginger botanical material may comprise, consist of, or consist essentially of, dust from the processing of ginger plant material, which may include the production of any products containing ginger material.

Rooibos botanical material

The botanical material maybe a rooibos botanical material. The rooibos botanical material may comprise or consist of material derived from rooibos.

SUBSTITUTE SHEET (RULE 26) ‘Rooibos, ‘rooibos material’, and ‘rooibos botanical material’ refers to any material derived from a plant from the genus Aspalathus, and in particular, Aspalathus linearis, in the family Fabaceae. Preferably, the rooibos plant is Aspalathus linearis, which is a bush whose leaves are widely used to make tea, known as bush tea, red tea, or redbush tea. The rooibos botanical material may comprise material from any part of a rooibos plant, and preferably, the rooibos botanical material may comprise or consist of rooibos leaf material. The rooibos botanical material may comprise vitamin C, and/or polyphenols, including flavanols, flavones, flavanones, dihydrochalcones, aspalathin, and/ or nothofagin. The rooibos botanical material may additionally or alternatively comprise benzoic and/ or cinnamic acids.

The pre-sized particulate rooibos botanical material may comprise material from any part of a rooibos plant. Preferably, the pre-sized particulate rooibos botanical material may comprise rooibos leaf material.

The rooibos botanical material may comprise, consist of, or consist essentially of, dust from the processing of rooibos plant material, which may include the production of any products containing rooibos material, such as tea. Pre-sized cellulose fibre

The use of pre-sized cellulose fibre specifically, rather than other structural fibrous materials such as pre-sized tobacco fibre, has been found to provide a number of advantages to the resulting aerosol generating material. In particular, in comparison to the use of other fibrous materials, the use of pre-sized cellulose fibre has surprisingly and advantageously been found to result in the production of strands of aerosol generating material that are thinner, lighter, more flexible and resistant to breakage, and that have a smoother surface. These properties provide various manufacturing and processing advantages.

This can be seen in the particle size distributions of aerosol generating materials produced using pre-sized cellulose fibre material versus pre-sized tobacco fibre. A aerosol generating material produced using pre-sized tobacco fibre and no pre-sized cellulose fibre material had a Dpio value of 0.7 mm, a Dpso value of 1.5 mm, and a Dp9O value of 4.0 mm, whereas the equivalent aerosol generating material produced using the corresponding pre-sized cellulose fibre, in this case, wood pulp, and no pre-

SUBSTITUTE SHEET (RULE 26) sized tobacco fibre (with all other parameters the same), had a Dpio value of 1.0 mm, a Dp5O value of 1.7 mm, and a Dpgo value of 5.0 mm. The significantly higher Dpgo value of the material produced using cellulose fibre indicates the longer lengths of the strands produced, and the higher Dpio value of the material indicates that less fine dust is present, due to reduced breakage of the strands. The measurement of the generation of fines material in this way, using Dpio, provides a comparative indicator of the capacity of strands to break allowing prediction of the suitability of the material for use in subsequent processing, such as in blending and smoking article manufacture. These advantageous properties provided by the use of pre-sized cellulose fibre, rather than other fibrous structural materials, also allow the production of aerosol generating material that has a higher filling value and a lower density. The lower density of the material means that an increased level of aerosol forming material such as glycerol may be carried by the aerosol generating material.

The initial material may comprise pre-sized cellulose fibre in an amount of up to 30%, 40%, or 50%, by mass. Preferably, the initial material may comprise pre-sized cellulose fibre in an amount of 1-25%, 2-22%, or 3-20%, by mass. Preferably, the initial material may comprise pre-sized cellulose fibre in an amount of 5.5-18%, by mass.

The pre-sized cellulose fibre comprises or consists of any suitable cellulose fibre material.

The cellulose fibre maybe an aromatic or non-aromatic cellulose fibre material. ‘Non- aromatic’ refers to any material having no odour or substantially no odour.

The cellulose fibre may comprise or consist of fibres derived from the cellulose found in woody plants. The cellulose fibre may comprise or consist of material or a combination of materials derived from jute, wood, grass, flax, bamboo, hemp, ramie, straw, or cotton.

The pre-sized cellulose fibre may comprise or consist of wood pulp.

Preferably, the pre-sized cellulose fibre is a non-tobacco cellulose fibre and does not contain or consist of tobacco or tobacco-derived material.

SUBSTITUTE SHEET (RULE 26) The pre-sized cellulose fibre may have a density greater than 70 g/L, greater than 75 g/L, greater than 80 g/L, or greater than 85 g/L.

The pre-sized cellulose fibre may have a density less than 110 g/L, less than 105 g/L, less than too g/L, or less than 95 g/L.

The pre-sized cellulose fibre may have a density of about 90 g/L.

The pre-sized cellulose fibre may have a moisture content, or may be conditioned to have a moisture content greater than 0.5%, greater than 1%, greater than 1.5%, or greater than 1.8%.

The pre-sized cellulose fibre may have a moisture content, or may be conditioned to have a moisture content less than 10%, less than 7%, less than 5%, or less than 3%.

The pre-sized cellulose fibre may have a moisture content, or may be conditioned to have a moisture content of about 2%.

The pre-sized cellulose fibre may comprise greater than 0.1%, greater than 0.5%, greater than 1%, or greater than 1.5%, by mass, of fibre having a particle size of greater than 200 micrometres. The pre-sized cellulose fibre may comprise less than 10%, less than 7%, less than 5%, or less than 3%, by mass, of fibre having a particle size of greater than 200 micrometres. The pre-sized cellulose fibre may comprise greater than 80%, greater than 90%, greater than 95%, or greater than 97%, by mass, of fibre having a particle size of less than 200 micrometres. The pre-sized cellulose fibre may comprise less than 99.9%, less than 99.5%, less than 99%, or less than 98.5%, by mass, of fibre having a particle size of less than 200 micrometres.

The pre-sized cellulose fibre may comprise greater than 10%, greater than 20%, greater than 25%, or greater than 27%, by mass, of fibre having a particle size of greater than 90 micrometres. The pre-sized cellulose fibre may comprise less than 40%, less than 35%, less than 32%, or less than 29%, by mass, of fibre having a particle size of greater than 90 micrometres.

SUBSTITUTE SHEET (RULE 26) The pre-sized cellulose fibre may comprise greater than 50%, greater than 60%, greater than 67%, or greater than 71%, by mass, of fibre having a particle size of less than 90 micrometres. The pre-sized cellulose fibre may comprise less than 90%, less than 80%, less than 75%, or less than 73%, by mass, of fibre having a particle size of less than 90 micrometres.

The pre-sized cellulose fibre may comprise greater than 70%, greater than 80%, greater than 85%, or greater than 87%, by mass, of fibre having a particle size of greater than 32 micrometres. The pre-sized cellulose fibre may comprise less than 99%, less than 95%, less than 92%, or less than 89%, by mass, of fibre having a particle size of greater than 32 micrometres.

The pre-sized cellulose fibre may comprise greater than 1%, greater than 5%, greater than 8%, or greater than 11%, by mass, of fibre having a particle size of less than 32 micrometres. The pre-sized cellulose fibre may comprise less than 30%, less than 20%, less than 15%, or less than 13%, by mass, of fibre having a particle size of less than 32 micrometres.

The pre-sized cellulose fibre may have a Dpgo value of between 130 micrometres and 200 micrometres, such as between 140 micrometres and 190 micrometres, between 150 micrometres and 180 micrometres, or between 160 micrometres and 170 micrometres. The pre-sized cellulose fibre may have a Dpgo particle size of about 165 micrometres.

The pre-sized cellulose fibre may have a Dpso value of between 50 micrometres and too micrometres, such as between 55 micrometres and 90 micrometres, between 60 micrometres and 80 micrometres, or between 65 micrometres and 75 micrometres. The pre-sized cellulose fibre may have a Dpso particle size of about 70 micrometres.

The pre-sized cellulose fibre may have a Dpio value of between 10 micrometres and 50 micrometres, such as between 15 micrometres and 40 micrometres, or between 20 micrometres and 30 micrometres. The pre-sized cellulose fibre may have a Dpio particle size of about 25 micrometres.

The pre-sized cellulose fibre may be a fine material. In particular, the pre-sized cellulose fibre may have a particle size of less than 2mm, preferably less than 1.5mm, and more preferably less than imm.

SUBSTITUTE SHEET (RULE 26) Composition of the initial material

The initial material may comprise a combination of pre-sized particulate botanical material and pre-sized cellulose fibre. By mass, the initial material comprises at least 20%, at least 30%, at least 40%, and preferably at least 50% pre-sized particulate botanical material. The botanical material may be a non-tobacco botanical material.

The initial material may contain less than 20%, 15%, 10%, or 5%, by mass, tobacco material. Preferably, the initial material contains no tobacco material.

The initial material may consist of a combination of pre-sized particulate botanical material and pre-sized cellulose fibre.

The initial material may comprise pre-sized particulate botanical material and pre- sized cellulose fibre wherein the mean, medial, and/or modal average particle size of the pre-sized particulate botanical material is smaller than that of the pre-sized cellulose fibre.

In some embodiments, the pre-sized botanical material may have a particle size distribution that substantially overlaps or corresponds in size with that of the pre-sized cellulose fibre.

In some embodiments, the pre-sized botanical material may have a larger particle size than the pre-sized cellulose fibre, for example, based on the average (modal, median, or mean) particle size.

The initial material may comprise an aerosol forming material or a combination of aerosol forming materials. The initial material may comprise a binder or a combination of binders.

The initial material may comprise an additional flavourant.

Aerosol forming material The initial material may comprise an aerosol forming material, which may also be referred to as a humectant.

SUBSTITUTE SHEET (RULE 26) The aerosol forming material may comprise one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

Preferably, the initial material may comprise glycerol and/or propylene glycol. The initial material may comprise an aerosol forming material in an amount of 1-30%, 3-28%, by mass. Preferably, the initial material may comprise an aerosol forming material in an amount of 5-25%, by mass. Preferably, the initial material may comprise an aerosol forming material in an amount of 5-20%, by mass, such as in an amount of at least or about 15%, by mass.

The aerosol generating material maybe a “high aerosol forming aerosol generating material”, and in these embodiments, the initial material and/or the aerosol generating material may comprise a relatively high aerosol forming material content, and may comprise about 10-30% by mass, such as 12-25% by mass, or 14-20% by mass, preferably about 15% by mass, of aerosol forming material. In such embodiments, the aerosol forming material may consist of or comprise glycerol and/or propylene glycol, and preferably substantially comprises glycerol. The filling value of the aerosol generating material in these embodiments maybe greater than 35, 36, or 38 cm3/iog, such as 40-46 cm3/iog. The initial material and/or the aerosol generating material may comprise 2-10% by mass or 3-8% by mass, preferably about 5% by mass, of binder. The binder may consist of or comprise CMC.

The aerosol generating material may be a “high filling value aerosol generating material”, and in these embodiments, the initial material and/or the aerosol generating material may comprise a lower aerosol forming material content, such as about 1-12% by mass, 2-10% by mass, 3-8% by mass, or 4-6% by mass, preferably about 5% by mass, of aerosol forming material. In such embodiments, the aerosol forming material may consist of or comprise glycerol and/or propylene glycol, and preferably substantially comprises glycerol. The filling value of the aerosol generating material in these embodiments may be greater than 40, 42, or 44 cm3/ 10g, such as 45-60 cm3/ 10g. The initial material and/ or the aerosol generating material may comprise 2-10% by mass or

SUBSTITUTE SHEET (RULE 26) 3-8% by mass, preferably about 5% by mass, of binder. The binder may consist of or comprise CMC.

In some embodiments, including some embodiments in which the aerosol generating material is a high filling value aerosol generating material, the cut speed, which is the rate at which the shearing gap surfaces move relative to one another (also referred to as the “cone rotation”, i.e. the rotation in rpm of the conical shearing member 10 shown in Figure 2) maybe at substantially maximum levels, such as between 80-100% of the maximum, preferably 90-95%. The maximum cut speed is about 850 rpm, and in some embodiments, including some embodiments in which the aerosol generating material is a high filling value aerosol generating material, the cut speed may be at least 700 rpm, 725 rpm, or 750 rpm. Preferably, the cut speed is 770-850 rpm, such as about 790-830, or about 810 rpm. In some embodiments, including some embodiments in which the aerosol generating material is a high filling value aerosol generating material, the cut pressure, which is the pressure imparted on the material in the shearing gap 9 shown in Figure 2 (also referred to as the pressure of the hydraulic system) may be at substantially maximum levels, such as between 80-100% of the maximum, preferably 90-95%. The maximum cut pressure is about 150 bar, and in some embodiments, including some embodiments in which the aerosol generating material is a high filling value aerosol generating material, the cut pressure may be at least 100 bar, 110 bar, or 120 bar. Preferably, the cut pressure is 125-148 bar, such as about 130-146 bar, 135-144 bar, or about 140-142 bar.

In some embodiments, including some embodiments in which the aerosol generating material is a high filling value aerosol generating material, the feeding rate of the material (also referred to as the rotation of the feed screw, i.e. the rotation in rpm of the conveyor screw of the conditioning device 20 shown in Figure 3) may be significantly lower than the maximal level, such between 30-50% or 35-45% of the maximum, preferably about 40%. The maximum speed of rotation of the feed screw is about 30 rpm, and in some embodiments, including some embodiments in which the aerosol generating material is a high filling value aerosol generating material, the feeding rate of the material may be 5-20 rpm, 6-18 rpm, 7-17 rpm, 8-16 rpm, 9-15 rpm, and is preferably 10-14 rpm or 11-13 ^rP^m, such as about 12 rpm.

SUBSTITUTE SHEET (RULE 26) In some embodiments, including some embodiments in which the aerosol generating material is a high filling value aerosol generating material, the material may be included in a component for a delivery system together with a second aerosol generating material. The second aerosol generating material may comprise aerosol forming material in an amount of at least 15% by mass. The second aerosol generating material may consist of or comprise, for example, an aerosol generating material produced by the disclosed method, such as a high aerosol forming aerosol generating material. The second aerosol generating material may consist of or comprise an aerosol generating material produced by a method different to the disclosed method, and may consist of or comprise, for example, an amorphous solid or dried gel comprising an aerosol forming material.

Binder

The initial material may comprise a binder.

The binder may comprise or consist of carboxymethyl cellulose (CMC), starch, guar gum, xanthan gum, acacia gum and/or hydroxypropyl cellulose (HPC).

Preferably, the binder may comprise CMC, guar gum, xanthan gum, and/or HPC. The use of these binders, and CMC in particular, in the production of aerosol generating material has been found to provide strands that are thinner, lightness, greater resistance to breakage, and to have a smoother surface, compared with formulations comprising other binders such as starch. Aerosol generating materials produced using these binders were also found to have a higher filling value, compared with formulations comprising other binders such as starch.

In some embodiments the binder may comprise xanthan gum, which has been found to provide aerosol generating material having strands of the greatest length and lowest density.

The use of CMC, guar gum, or xanthan gum, and CMC in particular, has been found to provide aerosol generating materials carrying an advantageously high level of aerosol forming material such as glycerol. The use of CMC, xanthan gum, or HPC has been found to provide aerosol generating material having an advantageously high filling value.

SUBSTITUTE SHEET (RULE 26) A combination of two, three, more, or more binders may be included in the initial material. In embodiments in which starch is used as a binder it maybe used in combination with a second binder.

The initial material may comprise a binder in a total amount of about 1-20%, 2-18%, 3- 15%, or 4-12%, by mass. Preferably the binder, if present, is included in the initial material in an amount of up to about 12%, by mass. The initial material may comprise a combination of starch and a second binder. In such embodiments, starch may be present in a greater amount than the second binder. Starch maybe present an amount of 0.5-12%, 1-10%, or 2-8%, such as about 3%, 4%, 5%, 6%, or 7%, by mass. The second binder used in combination with starch may be guar gum or xanthan gum. The second binder may be present in an amount of 0.5-8%, 1-7%, such as about 2%, 3%, 4%, 5% or 6%, by mass.

Specific botanical materials and formulations

In embodiments in which the botanical material is a mint botanical material and comprises or consists of material derived from a mint plant, the initial material may comprise botanical material in an amount of 60-75%, such as 62-73%, by mass. In such embodiments, the initial material may comprise cellulose fibre in an amount of 5-20%, such as 8-18%, by mass. The initial material may comprise an aerosol forming material, such as glycerol, in an amount of 10-20%, 12-18%, or about 15%, by mass. The initial material may further comprise a binder in a total amount of 3-6%, such as 4-5%, by mass. The binder may be a combination of two or more binders, which for example, may comprise a combination of starch and guar gum. The binders maybe included in substantially equal amounts, such as each comprising 1-3% or about 2%, by mass of the initial material, or the binder may be present in different amounts, such as, for example, in a ratio of between 1:2 and 1:5, or between 1:3 and 1:4.

The aerosol generating material comprising mint maybe a “high filling value aerosol generating material”, and in these embodiments, the initial material and/or the aerosol generating material may comprise about 1-12% by mass, 2-10% by mass, 3-8% by mass, or 4-6% by mass, preferably about 5% by mass, of aerosol forming material. In such embodiments, the aerosol forming material may consist of or comprise glycerol and/ or propylene glycol, and preferably substantially comprises glycerol. The initial material

SUBSTITUTE SHEET (RULE 26) and/or the aerosol generating material may comprise 2-10% by mass or 3-8% by mass, preferably about 5% by mass, of binder. The binder may consist of or comprise CMC. The initial material may comprise botanical material in an amount of 65-80%, such as 70-75%, or about 72%, by mass. In such embodiments, the initial material may comprise cellulose fibre in an amount of 10-25%, such as 15-20%, or about 18%, by mass. The filling value of the aerosol generating material in these embodiments may be greater than 48, 50, 52, or 54 cm3/iog, such as 56-70 cm3/iog.

The aerosol generating material comprising mint maybe a “high aerosol forming aerosol generating material”, and in these embodiments, the initial material and/or the aerosol generating material may comprise about 8-30% by mass, 10-25% by mass, 12- 18% by mass, or 14-16% by mass, preferably about 15% by mass, of aerosol forming material. In such embodiments, the aerosol forming material may consist of or comprise glycerol and/or propylene glycol, and preferably substantially comprises glycerol. The initial material and/ or the aerosol generating material may comprise 2- 10% by mass or 3-8% by mass, preferably about 5% by mass, of binder. The binder may consist of or comprise CMC. The initial material may comprise botanical material in an amount of 55-70%, such as 60-65%, or about 62%, by mass. In such embodiments, the initial material may comprise cellulose fibre in an amount of 10-25%, such as 15-20%, or about 18%, by mass. The filling value of the aerosol generating material in these embodiments maybe greater than 35, 38, or 40 cm3/iog, such as 41-55 cm3/iog.

In embodiments in which the botanical material is a eucalyptus botanical material and comprises or consists of material derived from a eucalyptus plant, the initial material may comprise botanical material in an amount of 70-75%, such as 72-74%, or about 73%, by mass. In such embodiments, the initial material may comprise cellulose fibre in an amount of 5-12%, such as 6-10%, or 8%, by mass. The initial material may comprise an aerosol forming material, such as glycerol, in an amount of 10-20%, 12-18%, or about 15%, by mass. The initial material may further comprise a binder in a total amount of 2-6%, such as 3-5%, or about 4%, by mass. The binder may be a combination of two or more binders, which for example, may comprise a combination of starch and guar gum. The binders may be included in substantially equal amounts, such as each comprising 1-3% or about 2%, by mass of the initial material, or the binder maybe present in different amounts, such as, for example, in a ratio of between 1:2 and 1:5, or between 1:3 and 1:4.

SUBSTITUTE SHEET (RULE 26) The aerosol generating material comprising eucalyptus maybe a “high filling value aerosol generating material”, and in these embodiments, the initial material and/or the aerosol generating material may comprise about 1-12% by mass, 2-10% by mass, 3-8% by mass, or 4-6% by mass, preferably about 5% by mass, of aerosol forming material. In such embodiments, the aerosol forming material may consist of or comprise glycerol and/or propylene glycol, and preferably substantially comprises glycerol. The initial material and/or the aerosol generating material may comprise 2-10% by mass or 3-8% by mass, preferably about 5% by mass, of binder. The binder may consist of or comprise CMC. The initial material may comprise botanical material in an amount of 75-90%, such as 80-85%, or about 82%, by mass. In such embodiments, the initial material may comprise cellulose fibre in an amount of 3-15%, such as 5-10%, or about 8%, by mass. The filling value of the aerosol generating material in these embodiments may be greater than 40, 42, or 44 citf/ 10g, such as 45-60 citf/ 10g. The aerosol generating material comprising eucalyptus maybe a “high aerosol forming aerosol generating material”, and in these embodiments, the initial material and/or the aerosol generating material may comprise about 8-30% by mass, 10-25% by mass, 12- 18% by mass, or 14-16% by mass, preferably about 15% by mass, of aerosol forming material. In such embodiments, the aerosol forming material may consist of or comprise glycerol and/ or propylene glycol, and preferably substantially comprises glycerol. The initial material and/or the aerosol generating material may comprise 2- 10% by mass or 3-8% by mass, preferably about 5% by mass, of binder. The binder may consist of or comprise CMC. The initial material may comprise botanical material in an amount of 65-80%, such as 70-75%, or about 72 or 73%, by mass. In such embodiments, the initial material may comprise cellulose fibre in an amount of 3-15%, such as 5-10%, or about 8%, by mass. The filling value of the aerosol generating material in these embodiments may be greater than 35, 38, or 40 citf/ 10g, such as 41- 55 cm3/iog. In embodiments in which the botanical material is a cinnamon botanical material and comprises or consists of material derived from a cinnamon plant, the initial material may comprise botanical material in an amount of 70-75%, such as 72-74%, or about 73%, by mass. In such embodiments, the initial material may comprise cellulose fibre in an amount of 5-12%, such as 6-10%, or 8%, by mass. The initial material may comprise an aerosol forming material, such as glycerol, in an amount of 10-20%, 12-18%, or about 15%, by mass. The initial material may further comprise a binder in a total

SUBSTITUTE SHEET (RULE 26) amount of 2-6%, such as 3-5%, or about 4%, by mass. The binder may be a combination of two or more binders, which for example, may comprise a combination of starch and guar gum. The binders may be included in substantially equal amounts, such as each comprising 1-3% or about 2%, by mass of the initial material, or the binder maybe present in different amounts, such as, for example, in a ratio of between 1:2 and 1:5, or between 1:3 and 1:4.

The aerosol generating material comprising cinnamon maybe a “high filling value aerosol generating material”, and in these embodiments, the initial material and/or the aerosol generating material may comprise about 1-12% by mass, 2-10% by mass, 3-8% by mass, or 4-6% by mass, preferably about 5% by mass, of aerosol forming material. In such embodiments, the aerosol forming material may consist of or comprise glycerol and/or propylene glycol, and preferably substantially comprises glycerol. The initial material and/or the aerosol generating material may comprise 2-10% by mass or 3-8% by mass, preferably about 5% by mass, of binder. The binder may consist of or comprise CMC. The initial material may comprise botanical material in an amount of 75-90%, such as 80-85%, or about 82%, by mass. In such embodiments, the initial material may comprise cellulose fibre in an amount of 3-15%, such as 5-10%, or about 8%, by mass. The filling value of the aerosol generating material in these embodiments may be greater than 42, 45, or 48 citf/ 10g, such as 49-60 citf/ 10g.

The aerosol generating material comprising cinnamon maybe a “high aerosol forming aerosol generating material”, and in these embodiments, the initial material and/or the aerosol generating material may comprise about 8-30% by mass, 10-25% by mass, 12- 18% by mass, or 14-16% by mass, preferably about 15% by mass, of aerosol forming material. In such embodiments, the aerosol forming material may consist of or comprise glycerol and/or propylene glycol, and preferably substantially comprises glycerol. The initial material and/or the aerosol generating material may comprise 2- 10% by mass or 3-8% by mass, preferably about 5% by mass, of binder. The binder may consist of or comprise CMC. The initial material may comprise botanical material in an amount of 65-80%, such as 70-75%, or about 72 or 73%, by mass. In such embodiments, the initial material may comprise cellulose fibre in an amount of 3-15%, such as 5-10%, or about 8%, by mass. The filling value of the aerosol generating material in these embodiments may be greater than 40, 42, or 44 citf/ 10g, such as 45- 55 cm3/iog.

SUBSTITUTE SHEET (RULE 26) In embodiments in which the botanical material is a clove botanical material, the initial material may comprise botanical material in a total amount of 60-75%, such as 65-70%, or 66-68%, by mass. The clove botanical material may comprise a combination of clove bud particulate material and clove powder. Particulate material from clove buds maybe included in an amount of 10-20%, such as 12-18%, or about 14-15%, by mass, and the remainder of the clove botanical material may be included in the form of powder, in an amount of 47-57%, such as 50-55%, or 51-53%, by mass. In such embodiments, the initial material may comprise cellulose fibre in an amount of 5-18%, such as 10-16%, or 12-14%, by mass. The initial material may comprise an aerosol forming material, such as glycerol, in an amount of 10-20%, 12-18%, or about 15%, by mass. The initial material may further comprise a binder in a total amount of 2-8%, such as 4-7%, or 5- 6%, by mass. The binder may be a combination of two or more binders, which for example, may comprise a combination of starch and guar gum. The binders may be included in substantially equal amounts, such as each comprising 1-4% or 2-3%, by mass of the initial material, or the binder may be present in different amounts, such as, for example, in a ratio of between 1:2 and 1:5, or between 1:3 and 1:4, such as 4:7.

The aerosol generating material comprising clove maybe a “high filling value aerosol generating material”, and in these embodiments, the initial material and/or the aerosol generating material may comprise about 1-12% by mass, 2-10% by mass, 3-8% by mass, or 4-6% by mass, preferably about 5% by mass, of aerosol forming material. In such embodiments, the aerosol forming material may consist of or comprise glycerol and/or propylene glycol, and preferably substantially comprises glycerol. The initial material and/or the aerosol generating material may comprise 2-10% by mass or 3-8% by mass, preferably about 5% by mass, of binder. The binder may consist of or comprise CMC.

The initial material may comprise botanical material in an amount of 65-85%, such as 70-80%, or about 75 or 76%, by mass. In such embodiments, the initial material may comprise cellulose fibre in an amount of 8-20%, such as 10-18%, 12-16% or about 14%, by mass. The filling value of the aerosol generating material in these embodiments may be greater than 42, 45, or 47 citf/ 10g, such as 48-60 citf/ 10g.

The aerosol generating material comprising clove maybe a “high aerosol forming aerosol generating material”, and in these embodiments, the initial material and/or the aerosol generating material may comprise about 8-30% by mass, 10-25% by mass, 12- 18% by mass, or 14-16% by mass, preferably about 15% by mass, of aerosol forming material. In such embodiments, the aerosol forming material may consist of or

SUBSTITUTE SHEET (RULE 26) comprise glycerol and/or propylene glycol, and preferably substantially comprises glycerol. The initial material and/or the aerosol generating material may comprise 2- 10% by mass or 3-8% by mass, preferably about 5% by mass, of binder. The binder may consist of or comprise CMC. The initial material may comprise botanical material in an amount of 55-75%, such as 60-70%, or about 65 or 66%, by mass. In such embodiments, the initial material may comprise cellulose fibre in an amount of 8-20%, such as 10-18%, 12-16% or about 14%, by mass. The filling value of the aerosol generating material in these embodiments may be greater than 35, 37, or 39 citf/ 10g, such as 40-55 cm3/iog.

In embodiments in which the botanical material is a lavender botanical material and comprises or consists of material derived from a lavender plant, the initial material may comprise botanical material in a total amount of 70-75%, such as 72-74%, or about 73%, by mass. The lavender botanical material may comprise a combination of material from lavender flowers and also from other parts of the lavender plant. Material from the lavender flower maybe included in an amount of 10-20%, such as 12-18%, or about 15%, by mass, and the remainder of the lavender botanical material may be included in an amount of 50-65%, such as 55-60%, or about 58%, by mass. In such embodiments, the initial material may comprise cellulose fibre in an amount of 5-12%, such as 6-10%, or 8%, by mass. The initial material may comprise an aerosol forming material, such as glycerol, in an amount of 10-20%, 12-18%, or about 15%, by mass. The initial material may further comprise a binder in a total amount of 2-6%, such as 3-5%, or about 4%, by mass. The binder may be a combination of two or more binders, which for example, may comprise a combination of starch and guar gum. The binders maybe included in substantially equal amounts, such as each comprising 1-3% or about 2%, by mass of the initial material, or the binder may be present in different amounts, such as, for example, in a ratio of between 1:2 and 1:5, or between 1:3 and 1:4.

The aerosol generating material comprising lavender maybe a “high filling value aerosol generating material”, and in these embodiments, the initial material and/or the aerosol generating material may comprise about 1-12% by mass, 2-10% by mass, 3-8% by mass, or 4-6% by mass, preferably about 5% by mass, of aerosol forming material. In such embodiments, the aerosol forming material may consist of or comprise glycerol and/or propylene glycol, and preferably substantially comprises glycerol. The initial material and/or the aerosol generating material may comprise 2-10% by mass or 3-8% by mass, preferably about 5% by mass, of binder. The binder may consist of or comprise

SUBSTITUTE SHEET (RULE 26) CMC. The initial material may comprise botanical material in an amount of 75-90%, such as 80-85%, or about 82%, by mass. In such embodiments, the initial material may comprise cellulose fibre in an amount of 3-15%, such as 5-10%, or about 8%, by mass. The filling value of the aerosol generating material in these embodiments may be greater than 40, 42, or 44 citf/ 10g, such as 46-60 citf/ 10g.

The aerosol generating material comprising lavender maybe a “high aerosol forming aerosol generating material”, and in these embodiments, the initial material and/or the aerosol generating material may comprise about 8-30% by mass, 10-25% by mass, 12- 18% by mass, or 14-16% by mass, preferably about 15% by mass, of aerosol forming material. In such embodiments, the aerosol forming material may consist of or comprise glycerol and/or propylene glycol, and preferably substantially comprises glycerol. The initial material and/or the aerosol generating material may comprise 2- 10% by mass or 3-8% by mass, preferably about 5% by mass, of binder. The binder may consist of or comprise CMC. The initial material may comprise botanical material in an amount of 65-80%, such as 70-75%, or about 72 or 73%, by mass. In such embodiments, the initial material may comprise cellulose fibre in an amount of 3-15%, such as 5-10%, or about 8%, by mass. The filling value of the aerosol generating material in these embodiments may be greater than 35, 37, or 39 citf/ 10g, such as 40- 55 cm3/iog.

The aerosol generating material comprising rooibos maybe a “high filling value aerosol generating material”, and in these embodiments, the initial material and/or the aerosol generating material may comprise about 1-12% by mass, 2-10% by mass, 3-8% by mass, or 4-6% by mass, preferably about 5% by mass, of aerosol forming material. In such embodiments, the aerosol forming material may consist of or comprise glycerol and/or propylene glycol, and preferably substantially comprises glycerol. The initial material and/or the aerosol generating material may comprise 2-10% by mass or 3-8% by mass, preferably about 5% by mass, of binder. The binder may consist of or comprise CMC, guar gum, and/ or starch. The initial material may comprise botanical material in an amount of 70-90%, such as 75-85%, or about 79%, by mass. In such embodiments, the initial material may comprise cellulose fibre in an amount of 5-20%, such as 8-15%, or about 12%, by mass. The filling value of the aerosol generating material in these embodiments maybe greater than 45, 48, or 50 cm3/iog, such as 52-60 cm3/iog.

SUBSTITUTE SHEET (RULE 26) The aerosol generating material comprising rooibos maybe a “high aerosol forming aerosol generating material”, and in these embodiments, the initial material and/or the aerosol generating material may comprise about 8-30% by mass, 10-25% by mass, 12- 18% by mass, or 14-16% by mass, preferably about 15% by mass, of aerosol forming material. In such embodiments, the aerosol forming material may consist of or comprise glycerol and/or propylene glycol, and preferably substantially comprises glycerol. The initial material and/or the aerosol generating material may comprise 2- 10% by mass or 3-8% by mass, preferably about 5% by mass, of binder. The binder may consist of or comprise CMC, guar gum, and/or starch. The initial material may comprise botanical material in an amount of 60-80%, such as 65-75%, or about 69%, by mass. In such embodiments, the initial material may comprise cellulose fibre in an amount of 5-20%, such as 8-15%, or about 12%, by mass. The filling value of the aerosol generating material in these embodiments maybe greater than 40, 42, or 44 cm3/iog, such as 46-55 cm3/iog.

The following specific compositions have been found to be particularly advantageous in terms of delivering, in use, high levels of optimally flavoured aerosol.

An initial material comprising mint botanical material, comprising the following composition (all % values are by mass): 73% particulate mint botanical material; 8% cellulose fibre; 2% starch; 2% guar gum; and 15% glycerol.

An initial material comprising mint botanical material, comprising the following composition (all % values are by mass): 69% particulate mint botanical material; 12% cellulose fibre; 2% starch; 2% guar gum; and 15% glycerol.

An initial material comprising mint botanical material, comprising the following composition (all % values are by mass): 62% particulate mint botanical material; 18% cellulose fibre; 4% starch; 1% guar gum; and 15% glycerol.

A formulation comprising mint botanical material for producing a “high filling value aerosol generating material”, comprising the following composition (all % values are by mass): 72% particulate mint botanical material; 18% cellulose fibre; 5% CMC; and 5% glycerol.

SUBSTITUTE SHEET (RULE 26) A formulation comprising mint botanical material for producing a “high aerosol forming aerosol generating material”, comprising the following composition (all % values are by mass): 62% particulate mint botanical material; 18% cellulose fibre; 4% starch; 1% guar gum; and 15% glycerol.

An initial material comprising eucalyptus botanical material, comprising the following composition (all % values are by mass): 73% particulate eucalyptus botanical material; 8% cellulose fibre; 2% starch; 2% guar gum; and 15% glycerol. A formulation comprising eucalyptus botanical material for producing a “high filling value aerosol generating material”, comprising the following composition (all % values are by mass): 82% particulate eucalyptus botanical material; 8% cellulose fibre; 5% CMC; and 5% glycerol. A formulation comprising eucalyptus botanical material for producing a “high aerosol forming aerosol generating material”, comprising the following composition (all % values are by mass): 72% particulate eucalyptus botanical material; 8% cellulose fibre; 5% CMC; and 15% glycerol. An initial material comprising cinnamon botanical material, comprising the following composition (all % values are by mass): 73% particulate cinnamon botanical material; 8% cellulose fibre; 2% starch; 2% guar gum; and 15% glycerol.

A formulation comprising cinnamon botanical material for producing a “high filling value aerosol generating material”, comprising the following composition (all % values are by mass): 82% particulate cinnamon botanical material; 8% cellulose fibre; 5% CMC; and 5% glycerol.

A formulation comprising cinnamon botanical material for producing a “high aerosol forming aerosol generating material”, comprising the following composition (all % values are by mass): 72% particulate cinnamon botanical material; 8% cellulose fibre; 5% CMC; and 15% glycerol.

An initial material comprising lavender botanical material, comprising the following composition (all % values are by mass): 15% particulate botanical material from

SUBSTITUTE SHEET (RULE 26) lavender flowers; 58% particulate botanical material from other parts of the lavender plant; 8% cellulose fibre; 2% starch; 2% guar gum; and 15% glycerol.

A formulation comprising lavender botanical material for producing a “high filling value aerosol generating material”, comprising the following composition (all % values are by mass): 82% particulate lavender botanical material; 8% cellulose fibre; 5% CMC; and 5% glycerol.

A formulation comprising lavender botanical material for producing a “high aerosol forming aerosol generating material”, comprising the following composition (all % values are by mass): 72% particulate lavender botanical material; 8% cellulose fibre; 5% CMC; and 15% glycerol.

An initial material comprising clove botanical material, comprising the following composition (all % values are by mass): 14.5% particulate botanical material from clove buds; 53% clove powder; 12% cellulose fibre; 3.5% starch; 2% guar gum; and 15% glycerol.

An initial material comprising clove botanical material, comprising the following composition (all % values are by mass): 14.5% particulate botanical material from clove buds; 51.5% clove powder; 14% cellulose fibre; 4% starch; 1% guar gum; and 15% glycerol.

A formulation comprising clove botanical material for producing a “high filling value aerosol generating material”, comprising the following composition (all % values are by mass): 76% particulate clove botanical material; 14% cellulose fibre; 5% CMC; and 5% glycerol.

A formulation comprising clove botanical material for producing a “high aerosol forming aerosol generating material”, comprising the following composition (all % values are by mass): 66% particulate clove botanical material; 14% cellulose fibre; 5% CMC; and 15% glycerol.

A formulation comprising rooibos botanical material for producing a “high filling value aerosol generating material”, comprising the following composition (all % values are by mass): 89% particulate rooibos botanical material (for example, 39.5% particulate

SUBSTITUTE SHEET (RULE 26) rooibos superior botanical material and 39.5% particulate rooibos fine cut botanical material); 12% cellulose fibre; 2% starch; 2% guar gum; and 5% glycerol.

A formulation comprising rooibos botanical material for producing a “high aerosol forming aerosol generating material”, comprising the following composition (all % values are by mass): 79% particulate rooibos botanical material (for example, 34.5% particulate rooibos superior botanical material and 34.5% particulate rooibos fine cut botanical material); 12% cellulose fibre; 2% starch; 2% guar gum; and 15% glycerol. Processing parameters

The method may comprise pre-conditioning the botanical material to one or more of the following parameters:

Temperature: 8o-i47[deg.] C;

Moisture: 5-25% OV by mass; and, Pressure (gas over-pressure): 1.2-4.5 bar.

In embodiments in which the botanical material consists of or comprises mint botanical material, the method may comprise pre-conditioning the mint botanical material to one or more of the following parameters: Temperature: i2O-i47[deg.] C, preferably 130-140 [deg.] C;

Moisture: 3-8% OV, preferably 4-6% OV, by mass; and, Pressure (gas over-pressure): 1.5-3.5 bar, preferably 2-3 bar.

In embodiments in which the botanical material consists of or comprises lavender botanical material, the method may comprise pre-conditioning the lavender botanical material to one or more of the following parameters:

Temperature: ioo-i4o[deg.] C, preferably no-i3o[deg.] C;

Moisture: 10-20% OV, preferably 12-15% OV, by mass; and,

Pressure (gas over-pressure): 2-4 bar, preferably 2.5-3.5 bar.

In embodiments in which the botanical material consists of or comprises eucalyptus botanical material, the method may comprise pre-conditioning the eucalyptus botanical material to one or more of the following parameters:

Temperature: i2O-i47[deg.] C, preferably i3O-i47[deg.] C; Moisture: 5-15% OV, preferably 8-12% OV, by mass; and,

Pressure (gas over-pressure): 1.5-4.5 bar, preferably 2.5-4.5 bar.

SUBSTITUTE SHEET (RULE 26) In embodiments in which the botanical material consists of or comprises cinnamon botanical material, the method may comprise pre-conditioning the cinnamon botanical material to one or more of the following parameters: Temperature: i2O-i47[deg.] C, preferably 130-140 [deg.] C;

Moisture: 10-20% OV, preferably more than 14% OV, by mass; and, Pressure (gas over-pressure): 1.2-3.5 bar, preferably 1.2-2 bar.

In embodiments in which the botanical material consists of or comprises clove botanical material, the method may comprise pre-conditioning the clove botanical material to one or more of the following parameters:

Temperature: 9O-i2o[deg.] C, preferably ioo-no[deg.] C; Moisture: 20-25% OV, preferably 21-24% OV, by mass; and, Pressure (gas over-pressure): 1.2-3.5 bar, preferably 1.2-2 bar.

Processing the initial material may comprise conveying it continuously. The step of processing the initial material may comprise conveying the initial material through a conveyor which builds up a mechanical pressure. The conveyor may comprise an extruder.

The present method of producing aerosol generating material has surprisingly been found to be provide particularly advantageous materials when much slower flow rates through the conveyer are used relative to those used in equivalent methods for processing tobacco material. Typically, corresponding tobacco processing methods require a throughput of 80-100 kg/hr. In contrast, the present method has advantageously been found to deliver improved materials, having high levels of botanical flavour and aroma, high filling values, and low density, when flow rates of 25- 75 kg/hr are used. Moreover, the use of lower flow rates, such as less than 60, 50, or 40 kg/hr, have been found to be associated with the provision of materials capable of carrying increased levels of aerosol forming materials.

In embodiments in which the botanical material comprises or consists of mint, material, the method can comprise a flow rate of 35-45 Kg/h, preferably 37-41 Kg/h.

SUBSTITUTE SHEET (RULE 26) In embodiments in which the botanical material comprises or consists of lavender, material, the method can comprise a flow rate of 55-68 Kg/h, preferably 60-64 Kg/h.

In embodiments in which the botanical material comprises or consists of eucalyptus material, the method can comprise a flow rate of 50-65 Kg/h, preferably 55-60 Kg/h.

In embodiments in which the botanical material comprises or consists of cinnamon material, the method can comprise a flow rate of 65-80 Kg/h, preferably 70-75 Kg/h. In embodiments in which the botanical material comprises or consists of clove material, the method can comprise a flow rate of 50-65 Kg/h, preferably 55-60 Kg/h.

The present method of producing aerosol generating material has also been found to be provide particularly advantageous materials when much slower flow rates of water through the conveyer are used relative to those used in equivalent methods for processing tobacco material. Improved materials, having high levels of botanical flavour and aroma, high filling values, and low density, have been found to be provided when water flow rates of less than 12 L/h are used. In embodiments in which the botanical material comprises or consists of mint, material, the method can comprise a water flow rate of less than i2L/h, preferably less than nL/h.

In embodiments in which the botanical material comprises or consists of eucalyptus or cinnamon material, the method can comprise a water flow rate of less than nL/h, preferably less than toL/h.

In embodiments in which the botanical material comprises or consists of lavender material, the method can comprise a water flow rate of less than loL/h, preferably less than 9L/h, less than 8L/h, or less than 7L/I1.

In embodiments in which the botanical material comprises or consists of clove material, the method can comprise a water flow rate of less than 7L/I1, preferably less than 5L/h, less than 4L/I1, or less than 3L/I1.

SUBSTITUTE SHEET (RULE 26) The present method of producing aerosol generating material has surprisingly been found to be advantageously performed at a lower expander pressure for processing the initial material than that used in equivalent methods for processing tobacco material. Typically, corresponding tobacco processing methods require the use of expander pressures in the range of 35-50 bar. The production of equivalent materials comprising tobacco which do not include a binder typically require pressures of at least 60 bar, such as in the range of between 60 bar and 70 bar.

Advantageously, the disclosed processing method may comprise pressurising the initial material to a pressure in the range of 15-35 bar. This pressure is much lower than that used in the production of a corresponding material comprising only tobacco. Moreover, the use of lower pressures, such as less than 30 bar, or less than 25 bar, have been found to provide materials that are capable of carrying the greatest levels of aerosol forming materials. The described processing conditions have also been found provide aerosol generating materials that retain and provide high levels of botanical flavour and aroma.

In embodiments in which the botanical material comprises or consists of mint, material, the method can comprise pressurising the initial material to a pressure in the range of 15-25 bar, preferably 18-21 bar.

In embodiments in which the botanical material comprises or consists of lavender, material, the method can comprise pressurising the initial material to a pressure in the range of 12-20 bar, preferably 14-17 bar.

In embodiments in which the botanical material comprises or consists of eucalyptus material, the method can comprise pressurising the initial material to a pressure of less than 35 bar, preferably 25-34.8 bar. In embodiments in which the botanical material comprises or consists of cinnamon material, the method can comprise pressurising the initial material to a pressure in the range of 25-34 bar, preferably 28-31 bar.

In embodiments in which the botanical material comprises or consists of clove material, the method can comprise pressurising the initial material to a pressure in the range of 12-23 bar, preferably 16-19 bar.

SUBSTITUTE SHEET (RULE 26) Processing the initial material may comprise heating the initial material to a temperature in the range of 6o-i8o°C, such as ioo-i7O°C, 12O-I6O°C, or 130-150 °C. The increase in temperature may be obtained by applying external heat and/ or is the result of creating mechanical pressure.

In some embodiments, pressurising the initial material to the pressure is performed before feeding the processed tobacco material through a shearing gap.

In some embodiments, the method comprises feeding the processed tobacco material through a shearing gap such that the processed tobacco material is defibrated by expansion The shearing gap may be arranged between shearing surfaces. A rotatable shearing member may comprise one of the shearing surfaces. The shearing member may comprise at least 140 grooves. The grooves may each have a maximum width in the circumferential direction of the shearing member of between 0.7mm and imm.

The method may further comprise exposing the processed tobacco material to a drop in pressure, resulting in flash evaporation.

The method may further comprise feeding the processed material through a shearing gap, such that the processed material is defibrated by expansion.

The shearing gap may have a width in the range of 10 to 2000 microns and, preferably, in the range of 50 to 300 microns.

The shearing gap may be arranged between shearing surfaces, wherein a rotatable shearing member comprises one of the shearing surfaces. The shearing member may comprise a plurality of grooves, such at least 80 grooves and, preferably, at least 90, 100, 120, 140, 160 or 180 grooves.

The grooves may each have a maximum width in the circumferential direction of the shearing member of between 0.3-2 mm, 0.5-1.5 mm, and preferably 0.7-1 mm.

SUBSTITUTE SHEET (RULE 26) The method can comprise rotating the shearing member at an angular velocity of at least 10 rpm and, preferably, at least too rpm, 300 rpm, 300 rpm or 350 rpm. In some embodiments, the method comprises rotating the shearing member at an angular velocity of 900 rpm or less. In particular, the method can comprise rotating the shearing member at an angular velocity of 500-850 rpm.

In embodiments in which the botanical material comprises or consists of mint, lavender, eucalyptus, and/or cinnamon material, the method can comprise rotating the shearing member at an angular velocity of 500-600 rpm.

In embodiments in which the botanical material comprises or consists of clove material, the method can comprise rotating the shearing member at an angular velocity of 800-850 rpm. Heating the initial material to the increased temperature may be performed before feeding the processed tobacco material through a shearing gap.

Pressurising the initial material to the increased pressure may be performed before feeding the processed tobacco material through a shearing gap.

Features of the product material

The aerosol generating material is preferably a non-continuous aerosol generating material. The aerosol generating material has surprisingly been found to be capable of retaining, carrying and delivering a much greater amount of aerosol forming material than an equivalent material produced by the same method but comprising only tobacco material. Typically, less than 15%, by mass, of an aerosol forming material can be included in equivalent tobacco material.

The present aerosol generating material may comprise 5-30% by mass, of aerosol forming material. Typically, the aerosol generating material may comprise more than 15% by mass, of aerosol forming material, such as more than 16%, 17%, 18%, 19%, or 20%. In some embodiments, the aerosol generating material may comprise more than 22%, 23%, 24%, or 25%, by mass, of aerosol forming material.

SUBSTITUTE SHEET (RULE 26) The present aerosol generating material may comprise up to 30%, 35%, or even 40%, by mass, of aerosol forming material.

Aerosol generating material comprising mint botanical material may comprise more than 22%, 23%, 24%, 25%, or 26%, by mass, of aerosol forming material, and may comprise up to 30%, 35%, or even 40%, by mass, of aerosol forming material.

Aerosol generating material comprising eucalyptus botanical material may comprise more than 15%, 16%, 17%, 18%, or 19%, by mass, of aerosol forming material, and may comprise up to 25%, 30%, 35%, or even 40%, by mass, of aerosol forming material.

Aerosol generating material comprising clove botanical material may comprise more than 17%, 18%, or 19%, by mass, of aerosol forming material, and may comprise up to 25%, 30%, 35%, or even 40%, by mass, of aerosol forming material.

Aerosol generating material comprising cinnamon botanical material may comprise more than 16%, 17%, 18%, or 19%, by mass, of aerosol forming material, and may comprise up to 25%, 30%, 35%, or even 40%, by mass, of aerosol forming material. Aerosol generating material comprising lavender botanical material may comprise more than 19%, by mass, of aerosol forming material, and may comprise up to 25%, 30%, 35%, or even 40%, by mass, of aerosol forming material.

The aerosol generating material has advantageously been found to be capable of providing a filling value that is at least that of an equivalent material produced by the same method but comprising only tobacco material. This is surprising in view of the generally more delicate and fine nature of the botanical material used in the production of the aerosol generating material. Typically, the filling value of an equivalent tobacco material is around 30 cm³/ 10g.

The aerosol generating material may have a filling value of greater than 30, 33, 35, 37, or 40 cm³/ 10g.

Filling (fill) value maybe calculated using the following equation: Fill value [cm³/ 10 ] = 0.1 x (V olumelcm³]/ Mass [ ])

At a measured moisture content of M%.

SUBSTITUTE SHEET (RULE 26) If necessary, the fill value may be corrected to a standard moisture content using the following equation: FV_O = ((FVx (1OO - Mo) x (M/Mo)^{o 8})/(1OO - M)

Where:

FV₀ = Fill value at moisture content M_o%

FV = Fill value determined at moisture content m%

Mo = Appropriate target moisture content (%) M = Actual moisture content of test tobacco (%)

0.8 = constant (Grandpre, 1987)

The increased fill value of the aerosol generating material relative to that of a material produced by the same method but containing only tobacco material is due to an increased flexibility of the disclosed aerosol generating material, resulting in reduced brittleness. Increased flexibility results from the inclusion of a binder in the initial material, and quantity used, by the smaller particle size range of the botanical material relative to the particle size of tobacco that is typically used, and/or as a result of the generally greater moisture content of the aerosol generating material.

As a result of the increased flexibility, strands of the aerosol generating material are less prone to snapping, and hence, the strand length distribution of the material is such that the strands of the material have an increased length relative to strands of a material produced by the same method from tobacco only.

The granularity of the aerosol generating material thus also contributes to the filling value. The presence of small particles, arising for example, due to breakage of strands, increases the density of the material and reduces the filling value. The disclosed aerosol generating material has been found to have a significantly lower proportion of small particles relative to similar materials comprising only tobacco, and this contributes to the high filling value of the material. The aerosol generating material may have a granulometry measured in terms of the % by mass of particles less than imm in size of less than 40 %.

SUBSTITUTE SHEET (RULE 26) The use of a binder has been found to increase the flexibility and reduce the brittleness of the aerosol generating material and thereby may be used to increase the filling value of the material. The aerosol generating material may have a Dpgo value of between 1.2mm and 6.0mm, such as between 1.5mm and 5.8mm, or between 1.9mm and 5.6mm. The aerosol generating material may have a Dpso value of between 1.1mm and 2.4mm, such as between 1.15mm and 2.2mm, or between 1.2mm and 2.0mm. The aerosol generating material may have a Dpio value of between 0.2mm and 1.5mm, such as between 0.4mm and 1.3mm, or between 0.6mm and 1.1mm.

Aerosol generating materials comprising mint botanical material may have a Dpgo value of between 4.0mm and 6.0mm, such as between 4.5mm and 5.5mm, or about 5.0mm. Aerosol generating materials comprising mint botanical material may have a Dpso value of between 1.2mm and 2mm, such as greater than 1.5mm and less than

1.8mm, or about 1.6mm. Aerosol generating materials comprising mint botanical material may have a Dpio value of between 0.9mm and 1.3mm, such as between imm and 1.2mm, or about 1.1mm. Aerosol generating materials comprising eucalyptus botanical material may have a Dpgo value of between 4.0mm and 6.0mm, such as between 4.5mm and 5.5mm, or about 5.0mm. Aerosol generating materials comprising eucalyptus botanical material may have a Dpso value of between 1.2mm and 2mm, such as greater than 1.5mm and less than 1.8mm, or about 1.65mm. Aerosol generating materials comprising eucalyptus botanical material may have a Dpio value of between 0.6mm and 1.0mm, such as between 0.7mm and 0.9mm, or about 0.8mm.

Aerosol generating materials comprising lavender botanical material may have a Dpgo value of between 1.5mm and 2.3mm, such as between 1.7mm and 2.1mm, or about 1.9mm. Aerosol generating materials comprising lavender botanical material may have a Dpso value of between 1.0mm and 1.4mm, such as between 1.1mm and 1.3mm, or about 1.2mm. Aerosol generating materials comprising lavender botanical material may have a Dpio value of between 0.4mm and 0.8mm, such as between 0.5mm and 0.7mm, or about 0.6mm.

SUBSTITUTE SHEET (RULE 26) Aerosol generating materials comprising cinnamon botanical material may have a Dp9O value of between 3.8mm and 4.6mm, such as between 4.0mm and 4.4mm, or about 4.2mm. Aerosol generating materials comprising cinnamon botanical material may have a Dpso value of between 1.2mm and 2mm, such as greater than 1.5mm and less than 1.8mm, or about 1.6mm. Aerosol generating materials comprising cinnamon botanical material may have a Dp 10 value of between 0.9mm and 1.3mm, such as between imm and 1.2mm, or about 1.1mm.

Aerosol generating materials comprising clove botanical material may have a Dpgo value of between 5.0mm and 6.2mm, such as between 5.3mm and 5.9mm, or about

5.6mm. Aerosol generating materials comprising clove botanical material may have a Dpso value of between 1.6mm and 2.4mm, such as between 1.8mm and 2.2mm, or about 2.0mm. Aerosol generating materials comprising clove botanical material may have a Dpio value of between 0.9mm and 1.3mm, such as between imm and 1.2mm, or about 1.1mm.

Component for delivery system

The aerosol generating material maybe included in a component. The component can further comprise a second material, which may be a smokable material, and/or an aerosol generating material.

The second material may be a second material, such as a second aerosol generating material. The second material may be an aerosol generating material that contains no botanical material. The second material may be an aerosol generating material that contains a different botanical material to that of the first aerosol generating material.

The second material may comprise tobacco. For example, the second material may comprise a reconstituted tobacco material, and/or a cut-rag tobacco. The second material may comprise a Kretek blend.

The component may comprise the disclosed aerosol generating material and a second material in the form of a blend. The blend may comprise the aerosol generating material in an amount of between 5% and 50% of the total material in the blend. For example, the blend may comprise the aerosol generating material in an amount of

SUBSTITUTE SHEET (RULE 26) between 10% and 40%, or between 15% and 30%, such as in an amount of about 12.5% or 25% of the total material in the blend.

The aerosol generating material may be configured such that the inclusion of the aerosol generating material results in, during use of the component, a modified and/ or improved flavour profile in comparison to an equivalent component that does not comprise the aerosol generating material, or that comprises a material containing no botanical material, such as only tobacco. In some embodiments, the aerosol generating material may be used in a blend as a taste and/or aroma modifying agent for use in aerosol delivery components. Thus, the aerosol generating materials providing high levels of taste or aroma of different botanical materials advantageously provides designers with a selection of materials that can be used individually or in combination to provide components having new and different aromas and flavour profiles.

The high filling value of the aerosol generating material provides further advantages for use in a blend because less of the material is required to provide the same filling capacity and product performance.

The aerosol generating material may be configured such that the inclusion of the aerosol generating material results in, during use of the component, an increased aerosol delivery in comparison to an equivalent component that does not comprise the aerosol generating material, or that comprises a material containing no botanical material, such as only tobacco.

The component may be for a non-combustible aerosol provision system.

In some embodiments, the non-combustible aerosol provision system is an aerosol generating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system.

Brief Description of the Drawings

Embodiments will now be described, by way of non-limiting example only, with reference to the drawings, in which:

SUBSTITUTE SHEET (RULE 26) FIG. 1 is a flow chart illustrating an embodiment of a method of processing botanical material into an aerosol generating material;

FIG. 2 is a schematic view of an embodiment of a pressure defibrating device;

FIG. 3 is a schematic view of a pressure conditioning and defibration system; and, FIG. 4 is a schematic view of another embodiment of a pressure conditioning and defibration system.

FIG. 5 is a graph showing the properties of aerosols produced by test articles containing aerosol generating material consisting of either: (A) rooibos aerosol generating material produced formulation T37.4; (B) rooibos aerosol generating material produced formulation T37.6; or (C) a reconstituted paper material produced from a similar formulation. The different attributes tested are as follows: 1 Hot puff; 2 ISS (first three puffs - highest); 3 Initial Flavour Intensity (first 3 puffs - average); 4 Impact; 5 Irritation; 6 Aerosol Body; 7 Visible Aerosol; 8 Botanical Flavour Intensity; 9 Flavour Consistency; 10 Aerosol Consistency; 11 Off notes; 12 Draw effort.

Detailed Description

Referring to FIG. 1, a method for processing botanical material into an aerosol generating material is shown. The aerosol generating material produced by the method may then be incorporated into a product. The product maybe a component for a delivery system as described herein, for example, an aerosol provision system.

In some embodiments, the aerosol provision system is a non-combustible aerosol provision system.

The component may be, for example, a rod of smokable material. In one particular embodiment, the component is a rod of smokable material for a tobacco heating system.

The product may be an article for use in or with a non-combustible aerosol provision system that releases compounds from an aerosol-generating material without combusting the aerosol-generating material, such as an electronic cigarette, a tobacco heating product, and hybrid systems to generate aerosol using a combination of aerosol-generating materials.

SUBSTITUTE SHEET (RULE 26) The product may be an article as used in a combustible aerosol provision system, such as a cigarette, cigarillo, cigar, or tobacco for pipes or for roll-your-own or for make- your-own cigarettes. Material

‘Botanical material’ in the present disclosure refers to any material derived from a plant. The botanical material maybe an aromatic botanical material. In this context, ‘aromatic’ refers to any material having a distinctive smell. Thus, an aromatic botanical material is any material that is capable of being identified by its aroma. The botanical material may comprise or consist of a flavourant, and thus the botanical material may be a flavourant botanical material. The botanical material is preferably an aromatic flavourant botanical material.

In some embodiments, the botanical material may contain no tobacco material and as such may be referred to as ‘non-tobacco botanical material’. Thus, non-tobacco botanical material is any material or mixture of materials derived from any plant or plants, that does not include any material from a plant from the genus Nicotiana.

The botanical material maybe a non-tobacco botanical material. In some embodiments, the non-tobacco botanical material is selected from a botanical material which comprises favourable aroma properties for use in a non-combustible aerosol provision system. For example, the non-tobacco botanical material may comprise relatively few aroma compounds compared to a traditional tobacco material; therefore, an aerosol produced from a non-tobacco botanical material may have a different profile of volatile compounds compared to an aerosol produced from a tobacco material. The non-tobacco botanical material may deliver an aerosol which is considered favourable by a consumer of tobacco-based delivery systems. In some embodiments, a non- tobacco botanical material may produce an aerosol, when heated, with a sensorial experience that is comparable to that provided by a conventional combustible product, such as a cigarette. In some embodiments, the non-tobacco botanical material is selected from seed-producing plants which do not develop persistent woody tissue and which are often valued for their medicinal or sensorial characteristics. In some embodiments, it may be preferable to provide an aerosol generating material, for use in a non-combustible aerosol provision system which does not comprise any tobacco plant material.

SUBSTITUTE SHEET (RULE 26) Thus, non-tobacco botanical material includes, but is not limited to, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, clove, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.

Preferably, the botanical material may comprise or consist of mint, eucalyptus, lavender, ginger, cinnamon, rooibos, and/or clove material.

‘Mint’, ‘mint material’, and ‘mint botanical material’ refers to any material derived from a plant from the genus Mentha in the family Lamiaceae. Any plant from this genus may be referred to as a ‘mint plant’. The mint botanical material may comprise or consist of material 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, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens.

The mint botanical material may comprise material from any part of a mint plant, and preferably, the mint botanical material may comprise or consist of mint leaf and/or mint stem material. ‘Eucalyptus’, ‘eucalyptus material’, and ‘eucalyptus botanical material’ refers to any material derived from a plant from the genus Eucalyptus, which contains various species of flowering trees, shrubs or mallees in the myrtle family, Myrtaceae. Any plant or tree from this genus maybe referred to as a ‘eucalyptus plant’ or ‘eucalyptus tree’.

SUBSTITUTE SHEET (RULE 26) The eucalyptus botanical material may comprise material from any part of a eucalyptus tree, and preferably, the eucalyptus botanical material may comprise or consist of eucalyptus leaf and/or eucalyptus stem and/or eucalyptus flower material. ‘Lavender’, ‘lavender material’, and ‘lavender botanical material’ refers to any material derived from a plant from the genus Lavandula in the family Lamiaceae. Any plant from this genus maybe referred to as a ‘lavender plant’.

The lavender botanical material may comprise material from any part of a lavender plant, and preferably, the lavender botanical material may comprise or consist of lavender flower and/or lavender bud material.

‘Ginger’, ‘ginger material’, and ‘ginger botanical material’ refers to any material derived from a plant from the genus Zingiber in the family Zingiberaceae. Any plant from this genus may be referred to as a ‘ginger plant’. Preferably, the ginger plant is Zingiber officinale, which is a flowering plant whose rhizome, known as ginger root or ginger, is widely used as a spice.

The ginger botanical material may comprise material from any part of a ginger plant, and preferably, the ginger botanical material may comprise or consist of ginger root/rhizome material.

‘Rooibos, ‘rooibos material’, and ‘rooibos botanical material’ refers to any material derived from a plant from the genus Aspalathus, and in particular, Aspalathus linearis, in the family Fabaceae. Preferably, the rooibos plant is Aspalathus linearis, which is a bush whose leaves are widely used to make tea, known as bush tea, red tea, or redbush tea.

The rooibos botanical material may comprise material from any part of a rooibos plant, and preferably, the rooibos botanical material may comprise or consist of rooibos leaf material.

‘Cinnamon’, ‘cinnamon material’, and ‘cinnamon botanical material’ refers to any material derived from a plant from the genus Cinnamomum in the family Lauraceae. Cinnamon is a spice obtained from the inner bark of various tree species from this

SUBSTITUTE SHEET (RULE 26) genus, and any tree from this genus may be referred to as a ‘cinnamon plant’ or ‘cinnamon tree’.

The cinnamon botanical material may comprise material from any part of a cinnamon plant, and preferably, the cinnamon botanical material may comprise or consist of cinnamon bark material.

‘Clove’, ‘clove material’, and ‘clove botanical material’ refers to any material derived from a plant from the species Syzygium aromaticum, which maybe referred to as a ‘clove plant’ or ‘clove tree’.

Preferably, clove material for use in the disclosed process may be derived from the bud of the clove plant material. The clove material may include, but is not limited to, the following type of clove material: Jawa, Bali, Manado, and/or Manado second grade.

The use of clove material may provide a distinctive flavour and sensorial experience for the end user. Cloves are known to have sensory effects including aroma, spicy, numbing, crackling, and throat soothing features among others. The organoleptic properties of the aerosol generating material produced by the disclosed method may thus provide improved flavour and sensorial properties over previous clove-containing smokable materials, such as Kretek materials. Botanical material for use in the disclosed method may consist of non-tobacco botanical material.

‘Tobacco’ and ‘tobacco material’ refers to any material derived from a plant from the genus Nicotiana.

A significant advantage of the disclosed method is provided in the efficiencies obtained by the use of particulate botanical material that would otherwise be considered waste, or a by-product of processing the botanical material for other purposes. For example, small pieces of botanical material generated in the processing of botanical material for other purposes, which would previously have been discarded as a waste product, may be used in the disclosed method in the production of an aerosol generating material.

SUBSTITUTE SHEET (RULE 26) Thus, as a result of the disclosed method, an aerosol generating material may be produced, which may be used in place of, or as a blend with, other materials as component for a delivery system, thereby providing economies in the production of these systems by the use of botanical material processing by-products.

‘Fines’ material refers to any plant-derived material for use in the disclosed process having a particle size of less than imm.

Aerosol forming material The aerosol generating material preferably comprises an aerosol forming material.

The aerosol forming material may comprise one or more constituents capable of forming an aerosol. In this context, an “aerosol forming material” is an agent that promotes the generation of an aerosol. An aerosol forming material may promote the generation of an aerosol by promoting an initial vaporisation and/ or the condensation of a gas to an inhalable solid and/or liquid aerosol. In some embodiments, an aerosol forming material may improve the delivery of flavour and aroma compounds from the aerosol generating material. The aerosol forming material may also function as a humectant.

When the aerosol generating material is heated, the aerosol forming material is aerosolised and entrains flavour and aroma compounds from the botanical material in the aerosol. As a result, aerosol forming material functions to improve the sensory performance of the aerosol generating material, by helping to transfer compounds such as flavour and aroma compounds from the aerosol generating material to the user.

An issue with including aerosol forming materials in components for delivery systems, such as non-combustible aerosol provision systems, is that it can be difficult to include a large amount of aerosol forming material in the component without detriment to the component, such as leaching of the aerosol forming material and/or discolouration of the component. In addition, it is not simply the amount of aerosol forming material that is important for the entrainment and delivery of compounds such as flavour compounds from the aerosol generating material to the user. Another important factor is how the aerosol forming material is contained within the aerosol generating material, and thus, how readily, in what quantities, and under what conditions, it may be

SUBSTITUTE SHEET (RULE 26) released when the component is in use. The present aerosol generating material comprising botanical material has surprisingly and advantageously been found to be capable of retaining, carrying, and delivering a much greater amount of aerosol forming material than an equivalent material produced by the same method but comprising only tobacco material. Typically, less than 15%, by mass, of an aerosol forming material can be included in equivalent tobacco material, whereas, in contrast, the present aerosol generating material may comprise more than 15%, by mass, of aerosol forming material. Indeed, the present aerosol generating material may comprise more than 16%, 17%, 18%, 19%, or 20%, by mass, of aerosol forming material. In some embodiments, the aerosol generating material may comprise more than 22%, 23%, 24%, or 25%, by mass, of aerosol forming material. In some embodiments, the present aerosol generating material may comprise up to 30%, 35%, or even 40%, by mass, of aerosol forming material.

Moreover, when used in the material produced by the disclosed method, the combination of aerosol forming material and botanical material has been found to provide surprisingly and unexpectedly enhanced levels of flavour and aroma from the botanical material to the user.

The aerosol forming material may comprise or consist of one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3- butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

In particular, the aerosol forming material may comprise or consist of glycerol and/or propylene glycol.

Binder

The aerosol forming material may comprise one or more binders.

Reconstituted tobacco-type materials that have been produced previously do not include a binder, but are formed from constituent mixtures merely by the application of mechanical pressure and elevated temperature. Indeed, the fact that these materials do

SUBSTITUTE SHEET (RULE 26) not include binders was seen as an advantage, for example, allowing the materials to be produced from fewer constituents using simplified processing methods.

The present inventors have surprisingly found, however, that the inclusion of a binder may, in some embodiments, be advantageous.

For example, the use of a binder has been found to provide aerosol forming materials, comprising botanical materials, having increased filling power. This offers a significant and highly advantageous tool for the production of materials with high filling power comprising botanical material.

The inclusion of a binder has been found to produce a more elastic and less brittle material. Increased levels of binder, however, provide materials that are difficult cut and process.

It has been found to be possible to further increase the filling power of these materials when a binder is used in combination with smaller particle sizes of pre-sized botanical material. Thus, the level of inclusion of binder and the particle size of the pre-sized botanical material provide useful and simple variables that the skilled person can adjust to obtain aerosol forming materials, comprising botanical materials, having different filling powers. The binder may comprise or consist of carboxymethyl cellulose (CMC), starch, guar gum, acacia gum, xanthan gum, and/or hydroxypropyl cellulose (HPC).

A combination of two, three, more, or more binders may be included in the initial material.

The initial material may comprise a binder in a total amount of about 1-20%, 2-18%, 3- 15%, or 4-12%, by mass. Preferably the binder, if present, is included in the initial material in an amount of up to about 12%, by mass. The initial material may comprise a combination of starch and a second binder. In such embodiments, starch may be present in a greater amount than the second binder.

SUBSTITUTE SHEET (RULE 26) Starch maybe present an amount of 0.5-12%, 1-10%, or 2-8%, such as about 3%, 4%, 5%, 6%, or 7%, by mass. The second binder used in combination with starch may be guar gum or xanthan gum. The second binder may be present in an amount of 0.5-8%, 1-7%, such as about 2%, 3%, 4%, 5% or 6%, by mass.

Overview

FIG. 1 shows a flow chart illustrating the disclosed method of processing botanical material and cellulose fibre into an aerosol generating material. The method may comprise the following steps: - Step o (So) of providing a pre-sized particulate botanical material, wherein the botanical material contains less than 95%, such as less than 50%, 20%, 10%, 5%, 1%, and preferably 0%, by mass, of tobacco material;

Step 1 (Si) of providing pre-sized cellulose fibre;

Step 2 (S2) of combining the pre-sized particulate botanical material with the pre-sized cellulose fibre to provide an initial material, wherein the initial material comprises at least 50%, such as 60-75%, by mass, of botanical material, and preferably 5-20%, by mass, of cellulose fibre;

Step (S3) of processing the initial material by setting the initial material to a predefined increased moisture content, subjecting the initial material to an increase in temperature and subjecting the initial material an increased pressure in order to bind the botanical material to the cellulose fibre;

Step (S4) of feeding the initial material through a shearing gap to form an aerosol generating material; and

Step (S5) of cooling the aerosol generating material.

It should be recognised that in some embodiments (not shown), one or more of steps (So), (Si), (S2), (S3), (S4) and/or (S5) maybe combined. For instance, the initial material may be conditioned whilst in the feeding apparatus, for example, being brought to initial conditions (such as, temperature, moisture and pressure) whilst travelling through a screw feeder of the feeding apparatus, or may be conditioned in the defibration device.

This pre-conditioning may take place under atmospheric conditions. Alternatively, in some embodiments the pre-conditioning process is operated at a pressure above atmospheric pressure. During pre-conditioning and/ or simultaneously during the

SUBSTITUTE SHEET (RULE 26) process (atmospheric or above atmospheric pressure), casing and flavouring agents may be added, in a manner known to those skilled in the art.

Preferably, step (S3) is operated on the basis of all of the above parameters for temperature, moisture and mechanical pressure. In other words, the material is brought to the above temperature, moisture and pressure values.

At step (S3), the initial material is subjected to an increased pressure, as explained above. At the step (S4) of feeding the initial material through a shearing gap to form an aerosol generating material, this increased pressure drops again. This usually takes place on discharge from a processing apparatus (e.g. extruder, screw conveyor, pistoncylinder unit) that subjects the initial material to the increased temperature, pressure and moisture. The drop in pressure on discharge from this shearing gap results in a flash evaporation, thereby causing the material to expand. This advantageously increases the filling capacity of the material.

At step (S3), the initial material is heated and placed under pressure to improve the flavour through chemically operated processes (e.g. Maillard reaction or caramelisation) and also to store energy to promote the by shearing and expansion through the shearing gap. The pressure generation and heating may be operated with standard plug screw feeders, the housings of which in particular may also be heated.

In some embodiments, the step (S3) of processing the initial material and/or the step (S4) of feeding the initial material through the shearing gap to form an aerosol generating material is performed using an apparatus of the configuration shown in Fig.

3-

Step Si - providing pre-sized particulate botanical material

Pre-sized particulate botanical material refers to botanical material that has been subjected to a pre-sizing step prior to combining the botanical material with the cellulose fibre to form the initial material.

The particle size distributions for different botanical materials that has been found to be suitable for use in producing the disclosed aerosol generating material are discussed above.

SUBSTITUTE SHEET (RULE 26) The step (Si) of providing the pre-sized particulate botanical material may comprise feeding the botanical material to a particle size reduction device that is configured to reduce the size of the botanical material. The particle size reduction device may be a milling/ cutting/ shredding device. The size reduction device may be a disc mill. A hammer mill, or other milling device, may alternatively be used.

The pre-sizing step may comprise passing the botanical material through an appropriately sieve or series of sieves, and discarding, or processing to reduce the size of, any material that does not pass through the sieve or sieves, as appropriate.

It has been found that pre-sizing the botanical material to provide the required particle size or particle size distribution improves the quality of the produced aerosol generating material, including the organoleptic qualities of the component or product.

Adjusting the specific particle sizes or size distribution also provides an approach for controlling and adjusting the filling power and density of the resulting aerosol generating material.

Step Si - providing pre-sized cellulose fibre

“Pre-sized cellulose fibre” refers to cellulose fibre material that has been subjected to a size analysis, and if necessary, to a pre-sizing step, prior to combining the material with the botanical material to form the initial material.

Pre-sizing the cellulose fibre material has been provide a number of significant advantages. For example, providing a combination of pre-sized cellulose fibre and presized botanical material has advantageously been found to reduce the separation of the botanical and cellulose materials once they have been mixed together and, for example, whilst disposed in a mixing silo.

In particular, pre-sizing the cellulose fibre and botanical material into the described size ranges has been found to reduce separation and de-mixing of the materials in the mixing silo and thus results in a more consistently produced material with a more consistent density.

SUBSTITUTE SHEET (RULE 26) It has also been found that pre-sizing the cellulose fibre and botanical material results in the manufacture of the material being more repeatable and consistent. Despite this, it has been found to be advantageous to operate the device at a much lower throughput than is used for the production of materials having a high tobacco content. Such materials are produced at a throughput of at least too kg/hr and, generally, at least no, 115 or 120 kg/hr. In contrast, the present method has advantageously been found to deliver improved materials when flow rates of 25-75 kg/hr are used.

Moreover, the use of lower flow rates, such as less than 60, 50, or 40 kg/hr, have been found to be associated with the provision of materials capable of carrying increased levels of aerosol forming materials.

In some embodiments, the step (Si) of providing the pre-sized cellulose fibre comprises providing cellulose fibre and feeding the cellulose fibre to a particle size reduction device that is configured to reduce the size of the cellulose fibre particles.

The particle size reduction device maybe a milling/cutting/shredding device. For example, the size reduction device may be a hammer mill, a centrifugal cutter, or a shredder.

The cellulose fibre maybe pre-sized without any milling/cutting/shredding of the material and, instead, the cellulose fibre is sorted, with material having a particle size outside a certain range being removed. This pre-sizing may involve sieving the material and rejecting material that does not pass through the sieve. The pre-sizing may be optical (e.g. using a microscope), using sieves, or using a sorting or sieving machine.

Step S2 - combining the materials to form the initial material

In some embodiments, the step (S2) of forming the initial material further comprises combining the pre-sized particulate botanical material and pre-sized cellulose fibre with further materials, such as additional fines material, one or more aerosol forming materials, and/ or one or more binder, for example.

Step S - processing the initial material

At step (S3), the initial material is subjected to increased mechanical pressure and in particular also increased temperature and moisture.

SUBSTITUTE SHEET (RULE 26) The initial material is brought to a pre-defined increased moisture content.

The material to be processed is also subjected to an increase in temperature, which may be obtained in particular by applying heat from outside and/or by mechanically generating pressure.

In some embodiments, the initial material is heated to a temperature of in the range of 6o-i8o°C, such as ioo-i7O°C, 12O-I6O°C, or 130-150 °C. The present method of producing aerosol generating material has surprisingly been found to be advantageously performed at a lower expander pressure than that used in equivalent methods for processing tobacco material. Typically, corresponding tobacco processing methods require the use of expander pressures in the range of 35-50 bar. The production of equivalent materials comprising tobacco which do not include a binder typically require pressures of at least 60 bar, such as in the range of between 60 bar and 70 bar.

Advantageously, the disclosed processing method may comprise pressurising the initial material to a pressure in the range of 20-35 bar. This pressure is much lower than that used in the production of a corresponding material comprising only tobacco. Moreover, the use of lower pressures, such as less than 30 bar, or less than 25 bar, have been found to provide materials that are capable of carrying the greatest levels of aerosol forming materials. As a result of step (S3), the botanical material and cellulose fibre are bound together to produce an aerosol generating material that may be used subsequently for the production of aerosol provision systems. This obviates the need for expensive separate processes. The initial material is therefore subjected to a mechanical pressure at an increased temperature and defined moisture level (e.g. in an extruder or a conveyor screwconditioner).

Due to the mechanical pressure, the particles of botanical material and cellulose fibre are pressed and bound together. As a result of this, the binding of the materials is so strong that the resulting the aerosol generating material is resistant to the normal

SUBSTITUTE SHEET (RULE 26) stresses which occur during subsequent processing. For example, botanical fines are not lost from the material as it is being conveyed by air under normal production conditions. Mechanical stability is therefore higher than is the case with conventional tobacco film materials.

The use of smaller particles of botanical material, such as a higher proportion of botanical fines, in the initial material is advantageous because it means that small particles of botanical material, which are generally a waste by-product of manufacturing that would otherwise be disposed of, can instead be recycled and productively reused.

The use of smaller particles of botanical material in the initial material is also advantageous because it has been found to increase the filling power of the material, particularly in combination with the use of a binder.

The processing preferably results in a product which is an aerosol generating material, in particular a fibrous and/or granular material or filler material. In other words, the method results in a product which is ready for consumption and can be used directly in an aerosol provision system. This is very different from producing a smokable material film (continuous material), which is more complex to produce and which still has to be cut and dried after production. The product obtained as a result of the present disclosure is of a size and moisture content which make it suitable for use directly as a filler material for aerosol provision systems, including tobacco heating devices. In some embodiments, the initial material is processed in batches, in particular pressed in batches, for example, in a piston-cylinder unit.

Step S4

At step (S4), the initial material is passed through the shearing gap to form an aerosol generating material.

On leaving the shearing gap and entering the atmosphere, a proportion of the entrained water evaporates abruptly which, in addition to the shearing effect, causes the material to be expanded in the shearing gap. The moisture of the material is reduced to in the range of 5-25% such as 7-20%, or 8-15% due to the flash evaporation, depending on the

SUBSTITUTE SHEET (RULE 26) process pressure and temperature, and ingredients contained in the material are also reduced to a certain extent.

It has been found to be advantageous if the shearing gap surfaces are moved relative to one another to prevent and clear blockages. This ensures that the full cross-sectional surface of the gap is used and constant physical conditions prevail at the gap, which ultimately results in a uniform product. To this end, it has also proved to be of advantage if the gap surfaces are structured or profiled, for example, having grooves, as will be described in more detail below.

The inventors have found that both filling value and quality score of the final material are maximised when the cut speed, which is the rate at which the shearing gap surfaces move relative to one another (also referred to as the “cone rotation”, i.e. the rotation in rpm of the conical shearing member 10 shown in Figure 2) is relatively high, such as 50-100% of the maximum, depending on the nature of the botanical material. The maximum speed of rotation of the shearing member 10 is about 850 rpm, and the optimum speed of rotation of the cone was found to be about 450-850 rpm depending on the botanical material. In some embodiments, including some embodiments in which the aerosol generating material is a high filling value aerosol generating material, the cut speed may be at substantially maximum levels, such as between 80-100% of the maximum, preferably 90-95%. In some embodiments, including some embodiments in which the aerosol generating material is a high filling value aerosol generating material, the cut speed may be at least 700 rpm, 725 rpm, or 750 rpm. Preferably, the cut speed is 770-850 rpm, such as about 790-830, or about 810 rpm.

The inventors have also found that both filling value and quality score of the final material are maximised when the cut pressure, which is the pressure imparted on the material in the shearing gap 9 shown in Figure 2 (also referred to as the pressure of the hydraulic system) is relatively high, such as 40-100% of the maximum. The maximum cut pressure is about 150 bar, and the optimum cut pressure was found to be 60-150 bar, such as about 142 bar. In some embodiments, including some embodiments in which the aerosol generating material is a high filling value aerosol generating material, the cut pressure may be at

SUBSTITUTE SHEET (RULE 26) substantially maximum levels, such as between 80-100% of the maximum, preferably 90-95%. In some embodiments, including some embodiments in which the aerosol generating material is a high filling value aerosol generating material, the cut pressure maybe at least 100 bar, 110 bar, or 120 bar. Preferably, the cut pressure is 125-148 bar, such as about 130-146 bar, 135-144 bar, or about 140-142 bar.

Both filling value and quality score have also been found by the inventors to be maximised when the feeding rate of the material (also referred to as the rotation of the feed screw, i.e. the rotation in rpm of the conveyor screw of the conditioning device 20 shown in Figure 3) was significantly lower than the maximal level, such as between 20- 60% of the maximum, such as 40%. The maximum speed of rotation of the feed screw is about 30 rpm, and the optimum speed of rotation of the feed screw was found to be about 6-18 rpm, such as about 12 rpm. In some embodiments, including some embodiments in which the aerosol generating material is a high filling value aerosol generating material, the feeding rate of the material maybe between 30-50% or 35-45% of the maximum, preferably about 40%. In some embodiments, including some embodiments in which the aerosol generating material is a high filling value aerosol generating material, the feeding rate of the material maybe 5-20 rpm, 6-18 rpm, 7-17 rpm, 8-16 rpm, 9-15 rpm, and is preferably 10-14 rpm or 11-13 ^rP^m, such as about 12 rpm.

Step S3

At step (S5), the aerosol generating material is cooled, for example from above ioo°C to room temperature, which may take place on a conveyor belt on the basis of air suction and may be operated from underneath.

During the cooling process the aerosol generating material loses more moisture due to cooling by evaporation thereby making it possible to arrive at the moisture level of the end product without a dryer. The cooled material may have a moisture content, for example, in the range of 5-25% and, preferably in the range of 8-15%.

Apparatus

Referring now to FIG. 2, a processing apparatus 1 is shown. In the present embodiment, the processing apparatus 1 is a pressure defibration device 1.

SUBSTITUTE SHEET (RULE 26) The pressure defibration device 1 comprises a chamber housing 2 with a conveyor screw 3 disposed therein, which is rotated by means of a drive mechanism 4, for example, an electric motor 4. The pressure defibration device 1 further comprises an initial material inlet 5A, a water inlet 6A and a casing and/or flavouring inlet 6B. The pressure defibration device 1 may further comprises a steam inlet 7.

The initial material is supplied to the initial material inlet 5A to enter the chamber housing 2, wherein the initial material passes along the chamber housing 2 upon rotation of the conveyor screw 3 such that the initial material passes from the initial material inlet 5A to an outlet 5B. At the outlet 5B of the chamber housing 2 is a head 8, which comprises a generally conical recess 8A. A shearing member 10 is received in the recess 8A. A shearing gap 9 is formed between the shearing member 10 and the inner wall of the recess 8A. The initial material is conveyed through the gap 9 by the screw 3. The outlet 5B of the chamber 2 is in the form of an orifice that communicates the interior of the chamber 2 with the recess 8A.

The orifice maybe disposed at the gap apex of the generally conical recess 8A. The discharged material is denoted by reference number 12.

In some embodiments, the shearing member 10 is in the form of a cone. The shearing gap 9 may be annular. The shearing member 10 is coupled to an actuator mechanism 11 that is configured to rotate the shearing member 10. The shearing member 10 can be rotated about its central axis, the rotation indicated by the bent arrow in FIG. 2. In some embodiments, the actuator mechanism 11 comprises an electric motor. In some embodiments, the actuator mechanism 11 is configured to move the shearing member 10 axially in order to adjust the size of the gap 9.

The axial movement of the shearing member 10 is indicated by the double arrow in

FIG. 2, showing that the shearing member 10 can be moved towards and away from the head 8. Therefore, the shearing member 10 can be securely retained in its axial position, but may also be moved axially. As a result of this, the width of the gap 9 can be

SUBSTITUTE SHEET (RULE 26) adjusted or adapted and, in some embodiments, a counter-pressure can be generated in the direction of the closure of the gap 9. The actuator mechanism 11 may be configured to move the shearing member 10 axially using a hydraulic or pneumatic actuator or using a linear gear arrangement such as a rack and pinion gear arrangement that is driven by an electric motor.

The first part of the processing of the initial material, at step (S3), takes place at a pressure above atmospheric pressure. This over pressure is generated as the initial material is conveyed along the chamber 2 via the screw 3 once it has been supplied to the inlet 5A.

The shearing gap 9 is disposed at the outlet end 5B of the chamber 2. The gap 9 virtually closes off the chamber 2 in the same manner as an extruder. The gap 9 may be generally annular in cross-section. The width of the gap 9 in the axial direction of the conveyor screwed is determined by the axial position of the shearing member 10. Therefore, in embodiments wherein the axial position of the shearing member 10 is adjustable, the width of the gap 9 is also adjustable. In step (S3), the initial material is subjected to increased pressure (of up to 50 bar) and increased temperature (in particular above ioo°C). In addition to the mechanical pressure which occurs due to the initial material being conveyed towards the gap 9, additional forces also act on the initial material because shearing forces act in the pitches of the conveyor screw in conjunction with the walls which cause the initial material to be cut and defibrated. The shearing effect can be assisted by introducing draughts through the housing wall or by introducing additional flow resistances. In addition, steam may be introduced at several points in order to regulate the moisture, the temperature and the pressure in the conveyor screw or in the chamber 2. As a result of introducing steam and due to the natural moisture of the botanical material and cellulose fibre, additional defibration and expansion of the initial material takes place on leaving the gap 9 because the water evaporates abruptly. Being under pressure, the moisture in the initial material evaporates abruptly as the pressure drops to atmospheric pressure downstream of the gap 9 and thus flash evaporation occurs. In some embodiments, the initial material is placed under pressure mechanically, in particular mechanically pressed against the shearing gap 9 in the chamber 2. This being

SUBSTITUTE SHEET (RULE 26) the case, the material may be placed under pressure by means of a conveyor screw, which presses the material towards the outlet end of the chamber 2 of a heatable screw conveyor, at which the shearing gap 9 is disposed. The initial material may also be coarsely pre-cut or coarsely pre-defibrated in the chamber 2 as it is fed towards the shearing gap.

In some embodiments, the shearing gap 9 is closed under pre-tensioning and is intermittently opened by the pressure of the initial material so that the material passes through the gap 9. Alternatively, the material may also advantageously be fed through a continuously opened shearing gap 9.

In some embodiments, the shearing gap 9 has a width in the range of 50 to 300 micrometres. In some embodiments, the pressure chamber 2 has a conveyor system in the form of a plug screw feeder for conveying the initial material from the inlet 5Ato the outlet 5B. In some embodiments pressure is generated by mechanical means, such as generated by a plug screw feeder for example, although other systems may also be used in principle within the context of the present disclosure, for example, using a piston system or alternatively, not mechanically or not only mechanically by using a gas pressure such as a pressurised gas supply.

If a plug screw feeder is used, in some embodiments it has reducing features which reduce the chamber volume in the region towards the outlet, for example, smaller screw pitches.

In some embodiments, mechanical pre-cutting features or pre-defibrating features are disposed in the pressure chamber 2. In one embodiment, a screw chamber pressureconditioning device is disposed upstream of the device proposed by the invention in the same pressure chamber housing or in another one connected upstream. A pressure conditioning device of this type is described in patent DE 103 04629 Al, for example, and can be combined with the pressure defibration device 1 of the present disclosure. The pressure conditioning device 1 may incorporate all the structural features illustrated in FIG. 1 and explained in the associated description of DE 103 04629 Al and reference may be made to these construction features for further details.

SUBSTITUTE SHEET (RULE 26) In some embodiments, the pressure chamber 2 comprises inlets for conditioning agents or casing agents and flavourings.

The conditioning and pressure defibration processes depends on the pressure conditions under which conditioning takes place. In some embodiments, the initial material is conditioned under atmospheric conditions and is fed by means of a feeding apparatus, for example, conveyor chutes or a conveyor belt, into the inlet 5A, for example, via a hopper. One or more of the constituents of the initial material may be conditioned separately. For instance, the botanical material and cellulose fibre maybe conditioned separately, or not conditioned, and then combined with each other and optionally other materials such as fines. In some embodiments, the botanical material and/ or cellulose fibre may be conditioned before being pre-sized.

In some embodiments, the feeding apparatus comprises a silo (not shown) and a screw feeder (not shown). The initial material is stored in the silo and supplies the screw feeder, wherein the screw feeder supplies the initial material to the inlet 5A of the pressure defibration device 1.

The feeding apparatus maybe configured to supply a predetermined flowrate of initial material to the processing apparatus 1. In some embodiments, the feeding apparatus is configured to supply initial material to the processing apparatus 1 at a flow rate in the range of 20 to too kg/h and, preferably, in the range of 25 to 80 kg/hour.

The conditioning process may take place at an axially intermediate point of the chamber 2 by introducing water and casing at the respective inlets 6A, 6B. In some alternative embodiments (not shown), the water and casing (and/or flavouring) are introduced at the same inlet, or only one of water and casing are introduced into the chamber 2. At step (S4), the initial material passes through the gap 9 and is subjected to shearing between the walls of the head 8 and the shearing member 10 and also the flash evaporation mentioned above takes place on the material leaving the gap 9. Thus, the gap 9 acts as a shearing gap 9. The shearing and the flash evaporation both contribute to a well defibrated aerosol generating product that can be used in aerosol provision systems.

SUBSTITUTE SHEET (RULE 26) In some embodiments, the shearing member 10 is rotated about its rotational axis in order to help prevent blockages from occurring in the gap 9. This rotation of the shearing member 10 may be continuous or intermittent or the direction of rotation may be alternated. This being the case, the rotation may be a full rotation or only a quarter or one third rotation or rotations of smaller/larger units. In an alternative embodiment (not shown), the shearing member 10 is stationary and the head 8 is rotated, for instance, being coupled to a drive mechanism. However, it should be recognised that in yet further embodiments, the head 8 and shearing member 10 do not rotate relative to each other.

In some embodiments, the head 8 and shearing member 10 comprise respective shearing surfaces 13, 14, wherein the gap 9 is formed between the shearing surfaces 13, 14. In some embodiments, the shearing surfaces 13, 14 are generally opposing. In some embodiments, one or both of the shearing surfaces 13, 14 has one or more surface formations, for example, grooves or other roughening such as protrusions or depressions. In some embodiments, the surface formations, for example, grooves, may have a depth in the radial direction of at least 0.2 or at least 1 mm. The surface formations promote shearing of the initial material and may also promote more homogenous pressure conditions which leads to a more homogenous end product. In some embodiments, the grooves extend parallel to the central axis of the shearing member 10.

In some embodiments, the shearing member 10 comprises more than 80 grooves and, preferably, at least 90, too, 120, 140, 160 or 180 grooves.

In some embodiments, the grooves each have a maximum width in the range of 0.5 to 1.5 mm. The width of each groove may be constant or may vary. It has been found that a smaller groove width results in smaller lighter fibres in the aerosol generating material. The width of the grooves is in the circumferential direction of the shearing member 10.

In some embodiments, the shearing surfaces 13, 14 are moveable apart from one another and towards one another. In some embodiments, the shearing member 10 is biased relative to the head 8 such that the shearing surfaces 13, 14 abut and thus the gap 9 is closed. Alternatively, the shearing surfaces 13, 14 are moveable apart from one another and towards one another with a fixed or fixedly adjustable distance, in which

SUBSTITUTE SHEET (RULE 26) case the shearing surfaces 13, 14 lie at a fixed distance of 10 to 2000 microns, and preferably 50 to 300 microns. These figures relate to smooth shearing surfaces 13, 14. Alternatively, if the shearing surfaces 13, 14 comprise, for example, grooves then the distance refers to the distance between the parts of the surfaces 13, 14 between the grooves.

In some embodiments, the grooves of the shearing member 10 extend longitudinally or transversely to the direction in which the shearing surfaces 13, 14 move. In some embodiments, the shearing surface 14 of the head 8 is stationary whereas the shearing surface 13 of the shearing member 10 is displaced axially. In some embodiments, the shearing surface 14 of the head 8 is displaced axially whereas the shearing surface 13 of the shearing member 10 is held stationary. In some embodiments, the shearing surface 14 of the head 8 is stationary whereas the shearing surface 13 of the shearing member 10 is rotated. In some embodiments, the shearing surface 14 of the head 8 is rotated whereas the shearing surface 13 of the shearing member 10 is held stationary.

Rotation and axial movement of the shearing surface(s) 13, 14 maybe caused by the same actuator mechanism 1. Alternatively, a first actuator mechanism may rotate one of the shearing surfaces 13, 14 whereas a second actuator mechanism may axially displace said one or the other one of the shearing surfaces 13, 14.

In some embodiments, the shearing surfaces 13, 14 are moved towards one another continuously or intermittently or in one or two directions or backwards and forwards.

In some embodiments, the gap 9 maybe an annular gap, preferably a conical gap.

At step (S5), the material is cooled. The material maybe cooled whilst being transported, for example, on a conveyor belt.

In some embodiments, the produced aerosol generating material has an average fibre diameter of less than 0.95 mm and, preferably, less than about 0.9 mm or 0.85 mm. In some embodiments, the average fibre diameter is about 0.8 mm or less. The average fibre diameter may be less than 0.8 mm. In some embodiments, the average fibre

SUBSTITUTE SHEET (RULE 26) diameter is in the range of 0.6 to 0.8 mm. A smaller average fibre diameter results in a lighter aerosol generating material that has a lower density.

Referring now to FIG. 3, another an embodiment of a processing apparatus is shown. The processing apparatus comprises a pressure defibration device 1 of the type described above with reference to FIG. 3. The processing apparatus further comprises a pressure conditioning device 20 connected upstream of the pressure defibration device 1. The pressure defibration device 1 and pressure conditioning device 20 form part of a combined pressure conditioning and defibration system.

The pressure conditioning device 20 may be of the type illustrated in particular in FIG.

1 of patent specification DE 103 04629 Al and described in the associated part of the description. The latter is included herein by way of reference. It has an initial material inlet 25 and a differential pressure-proof cellular wheel sluice 26 through which the initial material is introduced into the pressure chamber 21, where it is transported with the aid of a conveyor screw 22. The conveyor screw 22 is driven by a drive mechanism, for example, a motor 24.

Disposed at the end of the chamber 21 is an outlet 27 for the initial material, which feeds the inlet 5A of the pressure defibration device 1. In some embodiments, unlike the device described in patent specification DE 103 04629 Al there is no differential pressure-proof sluice at the outlet of the pressure conditioning device. Instead, the initial material is transferred to the inlet 5A of the pressure defibration device 1 by the pressure of the chamber 22.

In other embodiments, the outlet from the pressure conditioning chamber 22 is operated using a cellular wheel sluice and decreasing the pressure. In such embodiments, the initial material may be transferred to the pressure defibration process at a lower pressure than in the pressure conditioning chamber, for example, ambient pressure. In some embodiments, the initial material is first treated by the pressure conditioning device 20 and is then transported to a separate pressure defibration device 1. The initial material maybe manually transported between the pressure conditioning device 20 and pressure defibration device 1 or automatically, for example, using a conveyor belt or pneumatic conveyor.

SUBSTITUTE SHEET (RULE 26) However, it is preferable to avoid a drop in pressure during the transfer from the pressure conditioning device 20 to the pressure defibration device 1 to enable an above atmospheric pressure to be applied across the entire processing region from the start of conditioning through to the defibration process, as illustrated. The initial material is fed through the differential pressure-proof cellular wheel sluice 26. The pressureproofing of the sluice 26 at one end and the gap 9 which is always filled with defibrated material during operation make it possible to maintain a pressure above atmospheric pressure throughout the combined device. To this end, sealing of the cellular wheel sluice 26 may be optimised by heating its housing.

Once the initial material has been introduced into the chamber 22, the material is at a pressure above atmospheric pressure, which may be maintained by introducing steam to compensate for the natural leakage rates of the cellular wheel sluice 26 (gaps and spillage volumes). The initial material is heated by the steam and the moisture content increased. In principle, it would also be possible to operate a drying process in such a chamber using over-saturated steam, but when used for defibration, it is usually of advantage if the initial material introduced has a higher moisture content. The initial material is conveyed through the conditioning chamber 21 by the conveyor screw 22. Different settings may be used for this purpose (pitch of the screw, rotation speed and inclination of the chamber), by means of which the dwell time of the initial material can be set. In some embodiments the dwell time is between 2 and 10 minutes. After the pressure conditioning process, during which water, casing and/or flavouring material may also be added, the initial material is then transferred through the outlet 27 into the pressure defibration device 1. The process of introducing the initial material may also be made easier if the housing is also of a hopper-type design. In some embodiments, the typical dwell time of the initial material in the pressure defibration device 1 is less than 2 minutes, in particular less than 1 minute. The material may then leave the pressure defibration device 1 in the desired state described above.

Instead of the pressure conditioning screw, it would also be possible to use a conditioning screw operating at below atmospheric pressures.

SUBSTITUTE SHEET (RULE 26) In some embodiments, the pressure defibration device i comprises a single or twin screw conveyor with a shearing gap outlet for defibrating material. The shearing gap comprises an orifice, through which the material is sheared as it passes through. FIG. 4 illustrates another embodiment of a combined pressure conditioning and defibration system. The pressure conditioning device 20 and the pressure defibration device 1 are similar to those described above in reference to FIGS. 2 and 3, and therefore a detailed description will not be repeated hereinafter. A difference is that the conveyor screw of the conditioning device 20 and the defibration screw of the pressure defibration device 1 are provided on the same shaft and are driven by a single motor. If the same rotation speed is used for both screws, the different dwell times in the two process steps may be obtained using different methods, for example, by different crosssections/ volumes or release options in the region of the conditioning process. In the embodiments of FIGS. 3 and 4, the steam and conditioning agents, for example, water and casing, are introduced through the appropriate inlets of the pressure conditioning device 20. Corresponding water, conditioning and steam inlets are omitted from the pressure defib ration device 1. Flavouring and/ or casing can be introduced in both pressure ranges, i.e. in one or both of the pressure chambers, or at atmospheric pressure, i.e. outside of the chambers.

Water content

In some embodiments, the produced aerosol generating material has a water content in the range of between 6 and 20 %, between 7 and 18 %, or between 8 and 15 %. The water content of the material may be determined by any suitable method, such as, for example, using a Karl Fischer titrator.

In embodiments in which the produced aerosol generating material comprises or consists of mint botanical material, the water content of the aerosol generating material may be between 8 and 20 %, between 10 and 18 %, or between 12 and 15 %.

In embodiments in which the produced aerosol generating material comprises or consists of eucalyptus botanical material, the water content of the aerosol generating material may be between 6 and 12 %, between 7 and 10 %, or between 8 and 9 %.

SUBSTITUTE SHEET (RULE 26) In embodiments in which the produced aerosol generating material comprises or consists of cinnamon botanical material, the water content of the aerosol generating material may be between 8 and 16 %, between 10 and 14 %, or between 11 and 12 %. In embodiments in which the produced aerosol generating material comprises or consists of lavender botanical material, the water content of the aerosol generating material may be between 8 and 16 %, between 10 and 14 %, or between 11 and 12 %.

In embodiments in which the produced aerosol generating material comprises or consists of clove botanical material, the water content of the aerosol generating material maybe between 6 and 15 %, between 8 and 12 %, or between 9 and 10 %.

In embodiments in which the produced aerosol generating material comprises or consists of rooibos botanical material, the water content of the aerosol generating material may be between 8 and 20 %, between 10 and 18 %, or between 12 and 15 %.

Density index

In some embodiments, the produced aerosol generating material has a wet bulk density in the range of between 20 and 200 kg/m3, between 40 and 150 kg/m3, or between 60 and 120 kg/ m3. The wet bulk density may be calculated as mass/volume for a specific material.

In embodiments in which the produced aerosol generating material comprises or consists of mint botanical material, the wet bulk density of the aerosol generating material maybe between 80 and 150 kg/m3, such as between too and 130 kg/m3, or between 110 and 120 kg/m3, such as about 114 kg/m3.

In embodiments in which the produced aerosol generating material comprises or consists of eucalyptus botanical material, the wet bulk density of the aerosol generating material may be between 50 and too kg/m3, such as between 60 and 80 kg/ m3, such as about 70 kg/m3.

In embodiments in which the produced aerosol generating material comprises or consists of cinnamon botanical material, the wet bulk density of the aerosol generating material maybe between 80 and 150 kg/m3, such as between 90 and 120 kg/m3, or between too and 110 kg/m3, such as about 103 kg/m3.

SUBSTITUTE SHEET (RULE 26) In embodiments in which the produced aerosol generating material comprises or consists of lavender botanical material, the wet bulk density of the aerosol generating material maybe between 50 and 120 kg/m3, such as between 70 and too kg/m3, or between 80 and 90 kg/ m3, such as about 83 kg/ m3.

In embodiments in which the produced aerosol generating material comprises or consists of clove botanical material, the wet bulk density of the aerosol generating material maybe between 60 and 130 kg/m3, such as between 80 and 110 kg/m3, or between 90 and too kg/m3, such as about 95 kg/m3.

In embodiments in which the produced aerosol generating material comprises or consists of rooibos botanical material, the wet bulk density of the aerosol generating material maybe between 50 and too kg/m3, such as between 65 and 80 kg/m3.

Delivery Systems

The present disclosure also relates to manufacturing a component for a delivery system such as an aerosol provision system. The delivery system described herein can be implemented as a non-combustible aerosol provision system or an aerosol-free delivery system.

The method comprises combining the aerosol generating material with a tobacco material, for example, cut tobacco, to form a mixture or blend; and then forming the component from the mixture or blend.

The aerosol generating material, particularly in embodiments in which the botanical material consists of or comprises clove botanical material, may be combined with a Kretek tobacco material in a component for a delivery system.

In some embodiments, for a non-combustible product, for example, a non-combustible aerosol provision system, the mixture may comprise at least 5%, and up to 100% aerosol generating material, by mass. In some embodiments, the aerosol generating material may be used in a blend with tobacco and/or one or more other material. Depending on the desired sensory

SUBSTITUTE SHEET (RULE 26) properties and the type of botanical material used in the aerosol generating material, the blend may comprise, for example, greater than 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 99% aerosol generating material. For example, the blending may be a blend with tobacco material and may comprise a blend ratio (tobacco: aerosol generating material) of, for example, 95:5, 90:10, 85:15, 80:20, 75:25, 70:30, 65:53, 60:40, 55: 45, 50:50, 45:55, 40:60, 35:65, 30:70, 25:75, 20:80, 15:85, 10:90, 5:95%, or substantially 0:100.

In some embodiments, the aerosol-generating material may be combined with an “amorphous solid”, which may alternatively be referred to as a “monolithic solid” (i.e. non-fibrous), which may comprise aerosol forming material. In some embodiments, the amorphous solid maybe a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the aerosolgenerating material may for example comprise from about 50wt%, 6owt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or ioowt% of amorphous solid.

In some embodiments, there is provided a component for a non-combustible aerosol provision system, the component comprising aerosol generating material. The method as described herein results in aerosol generating material which is expanded, and expanded material can be provided in, for instance, an aerosol generating portion of an article for use in the non-combustible aerosol provision system, or the non-combustible delivery system, as described herein. There is also provided a non-combustible delivery system or a non-combustible aerosol delivery system comprising aerosol generating material, for instance the material produced by the methods described herein. The non-combustible aerosol provision system can, for instance, be a tobacco heating product, or a hybrid system to generate aerosol using a combination of aerosolgenerating materials, where one of the materials is an aerosol generating material.

In some embodiments, the component is for a combustible aerosol provision system or for a non-combustible aerosol provision system. In some embodiments, the component is a rod of smokable material.

The present disclosure further relates to an aerosol provision system and to parts of the aerosol provision system comprising aerosol generating material manufactured according to the present disclosure.

SUBSTITUTE SHEET (RULE 26) As used herein, the term “delivery system” is intended to encompass systems that deliver at least one substance to a user, and includes: combustible aerosol provision systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for roll-your-own or for make-your-own cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokable material); non-combustible aerosol provision systems that release compounds from an aerosol-generating material without combusting the aerosol-generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol-generating materials; and aerosol-free delivery systems that deliver the at least one substance to a user orally, nasally, transdermally or in another way without forming an aerosol, including but not limited to, lozenges, gums, patches, articles comprising inhalable powders, and oral products such as oral tobacco which includes snus or moist snuff, wherein the at least one substance may or may not comprise nicotine.

As used herein, the term “aerosol provision system” is intended to encompass combustible and non-combustible aerosol provision systems that deliver at least one substance to a user, and includes: combustible aerosol provision systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for roll-your-own or for make-your-own cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokable material); non-combustible aerosol provision systems that release compounds from an aerosol-generating material without combusting the aerosol-generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol-generating materials.

According to the present disclosure, a “combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is combusted or burned during use in order to facilitate delivery of at least one substance to a user.

In some embodiments, the delivery system is a combustible aerosol provision system, such as a system selected from the group consisting of a cigarette, a cigarillo and a cigar.

SUBSTITUTE SHEET (RULE 26) In some embodiments, the disclosure relates to a component for use in a combustible aerosol provision system, such as a filter, a filter rod, a filter segment, a tobacco rod, a spill, an aerosol-modifying agent release component such as a capsule, a thread, or a bead, or a paper such as a plug wrap, a tipping paper or a cigarette paper.

According to the present disclosure, a “non-combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.

In some embodiments, the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system. In some embodiments, the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol-generating material is not a requirement. In some embodiments, the non-combustible aerosol provision system is an aerosolgenerating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system.

In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine.

In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product.

Typically, the non-combustible aerosol provision system may comprise a non- combustible aerosol provision device and a consumable for use with the non- combustible aerosol provision device.

SUBSTITUTE SHEET (RULE 26) In some embodiments, the disclosure relates to consumables comprising aerosolgenerating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure.

In some embodiments, the non-combustible aerosol provision system, such as a noncombustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source.

In some embodiments, the non-combustible aerosol provision system may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/or an aerosol-modifying agent.

In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and/ or an aerosol-modifying agent.

In some embodiments, the substance to be delivered may be an aerosol-generating material or a material that is not intended to be aerosolised. As appropriate, either material may comprise one or more active constituents, one or more flavours, one or more aerosol-former materials, and/or one or more other functional materials.

Active Substance In some embodiments, the substance to be delivered comprises an active substance.

The active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropics, psychoactives. The active substance may be naturally occurring or synthetically obtained. The active substance may comprise for example nicotine, caffeine, taurine, theine, vitamins such as B6 or

SUBSTITUTE SHEET (RULE 26) B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical. The active substance can comprise a nicotine salt. The nicotine salt may be nicotine benzoate, nicotine levulinate, nicotine citrate, nicotine lactate, or combinations thereof.

In some embodiments, the active substance comprises nicotine. Nicotine may be applied to the aerosol-generating material using any suitable method. For example, in some embodiments, nicotine may be applied to the aerosol-generating material by means of a suitable applicator, such as a spray. In addition or alternatively, in some embodiments, nicotine may be combined with the aerosol generating agent such as glycerol for inclusion in the aerosol-generating material. The nicotine or nicotine salt may be included in the material in a final amount of about 0.1% to about 5% by weight of the aerosol-generating material. For example, the total amount of nicotine or nicotine salt in the material maybe from about 0.2% to about 4%, from about 0.5% to about 3%, such as about 1% or about 2% by weight of the aerosol-generating material.

The nicotine content may be determined by any suitable method, such as, for example, using gas chromatography, or any other method that is used in the art to quantify the level of secondary alkaloids in tobacco. In some embodiments, including some embodiments in which the active substance comprises nicotine, the aerosol generating material may comprise an acid. As a result, the aerosol-generating materials comprising acid may produce an aerosol with an appropriate composition such as nicotine content. The inclusion of an acid has been found to improve the release of other substances, such as nicotine, from the material. The total amount of the acid maybe from about 0.1% to about 5% by weight of the aerosol-generating material. For example, the total amount of the acid maybe from about 0.1% to about 5%, from about 0.5% to about 5%, from about 1% to about 5%, from about 1.5% to about 5%, from about 2% to about 5%, or from about 2.5% to about 5% by weight of the aerosol-generating material. For example, the total amount of the acid maybe from about 2.5% to about 5%, from about

SUBSTITUTE SHEET (RULE 26) 2.5% to about 4.5%, from about 2.5% to about 4%, from about 2.5% to about 3.5%, or from about 2.5% to about 3% by weight of the aerosol-generating material.

In some embodiments, the aerosol-generating material comprises the acid in an amount (i.e. moles of acid) from about 50% to about 200%, from about 75% to about 150%, from about 85% to about 140%, from about 95% to about 135%, from about 105% to about 130%, or from about 110% to about 125% relative to the moles of nicotine in the material. In some embodiments, the aerosol-generating material comprises the acid in an amount (i.e. moles of acid) from about 100% to about 200%, from about 100% to about 180%, from about 110% to about 180%, from about 120% to about 180%, from about 130% to about 180%, or from about 135% to about 180% relative to the moles of nicotine in the material.

The acid maybe included in a ratio of between about 0.5 and about 2.5 moles, relative to the moles of free base nicotine.

The acid may be applied to the aerosol-generating material using any suitable method. The acid may be applied to the material together with another substance, such as nicotine and/or an aerosol forming material, or maybe applied separately. For example, in some embodiments, the ratio of the acid and aerosol forming material in the aerosol-generating material is from about 1:2 to about 1:50 (acid: aerosol forming material).

The acid may be applied to the aerosol-generating material using any suitable method. In some embodiments, the acid may be included in the formulation of the aerosolgenerating material prior to, or as it is being produced. Additionally or alternatively, the acid may be applied to the aerosol-generating material after it has been produced.

In some embodiments, the acid is selected from the group consisting of lactic acid, levulinic acid, benzoic acid, citric acid, 2-methylbutyric acid, or 2-methylvaleric acid. In some embodiments, the acid is lactic acid. In some embodiments, the acid is levulinic acid. The term lactic acid is synonymous with the term 2-hydroxypropanoic acid and covers both D and L enantiomers separately or a mixture thereof. For example, the lactic acid can be a mixture (for example a racemic mixture) of D-2-hydroxypropanoic acid and L-2-hydroxypropanoic acid. The term levulinic acid is synonymous with the term 4-oxopentanoic acid.

SUBSTITUTE SHEET (RULE 26) In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12. As noted herein, the active substance may comprise one or more constituents, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.

As noted herein, the active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof. As used herein, the term "botanical" includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like. Alternatively, the material may comprise an active compound naturally existing in a botanical material, obtained synthetically. The material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like. Example botanicals include any of the botanical materials listed above.

In some embodiments, the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof.

In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is mint, eucalyptus, lavender, ginger, cinnamon, rooibos, and/or clove material. In some embodiments, the substance to be delivered comprises a flavour.

As used herein, the terms "flavour" and "flavourant" refer to materials which, where local regulations permit, may be used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavour materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits,

SUBSTITUTE SHEET (RULE 26) Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, clove, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavour enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They maybe imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas. In some embodiments, the flavour comprises menthol, spearmint and/ or peppermint.

In some embodiments, the flavour comprises eugenol. In some embodiments, the flavour comprises eucalyptus. In some embodiments, the flavour comprises lavender.

In some embodiments, the flavour comprises ginger. In some embodiments, the flavour comprises cinnamon. In some embodiments, the flavour comprises rooibos.

In some embodiments, the flavour comprises flavour components extracted from tobacco. In some embodiments, the flavour comprises flavour components extracted from cannabis. In some embodiments, the flavour may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucolyptol, WS-3.

SUBSTITUTE SHEET (RULE 26) The aerosol-generating material may comprise one or more active substances and/or flavours, and optionally one or more other functional material. The one or more other functional materials may comprise one or more of pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants.

The material may be present on or in a support, to form a substrate. The support may, for example, be or comprise paper, card, paperboard, cardboard, reconstituted material, a plastics material, a ceramic material, a composite material, glass, a metal, or a metal alloy. In some embodiments, the support comprises a susceptor. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is on one or either side of the material.

A consumable is an article comprising or consisting of aerosol-generating material, part or all of which is intended to be consumed during use by a user. A consumable may comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and/ or an aerosol-modifying agent. A consumable may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosol-generating material to generate aerosol in use. The heater may, for example, comprise combustible material, a material heatable by electrical conduction, or a susceptor.

A susceptor is a material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically-conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the heating material. The heating material maybe magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor maybe both electrically-conductive and magnetic, so that the susceptor is heatable by both heating mechanisms. The device that is configured to generate the varying magnetic field is referred to as a magnetic field generator, herein.

SUBSTITUTE SHEET (RULE 26) An aerosol-modifying agent is a substance, typically located downstream of the aerosol generation area, that is configured to modify the aerosol generated, for example by changing the taste, flavour, acidity or another characteristic of the aerosol. The aerosolmodifying agent may be provided in an aerosol-modifying agent release component, that is operable to selectively release the aerosol-modifying agent

The aerosol-modifying agent may, for example, be an additive or a sorbent. The aerosol-modifying agent may, for example, comprise one or more of a flavourant, a colourant, water, and a carbon adsorbent. The aerosol-modifying agent may, for example, be a solid, a liquid, or a gel. The aerosol-modifying agent maybe in powder, thread or granule form. The aerosol-modifying agent may be free from filtration material.

An aerosol generator is an apparatus configured to cause aerosol to be generated from the aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to heat energy, so as to release one or more volatiles from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to cause an aerosol to be generated from the aerosol-generating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy.

Examples

Examples 1-4 describe initial experiments performed by the inventors to investigate how the formulation of an initial material comprising a botanical material and cellulose fibre relates to the resulting product, and in particular to investigate the production of a material, comprising particulate botanical material, having an improved filling value, and capable of carrying a high level of aerosol forming material. In these initial experiments, tobacco material was used as the botanical material. This is because tobacco is a readily available and well-understood material. Tests with tobacco allowed the inventors to understand how the parameters and formulations influenced the resulting materials. Materials prepared using non-tobacco botanical materials could then be produced having the desired properties. Ultimately, the aim was to produce an aerosol generating material with high filling power, low density (to

SUBSTITUTE SHEET (RULE 26) enable the carriage and delivery of high levels of aerosol forming material such as glycerol), and to provide new aromas and new flavour profiles.

Example 1 In this example, aerosol-generating material comprising 65% tobacco material was produced. This material is referred to as Ti. The formulation of the initial material that was found to be suitable for producing aerosol-generating material comprising 65% tobacco material is provided below.

The parameters used in the production of the material were as follows:

The resulting aerosol generating material had the following properties:

SUBSTITUTE SHEET (RULE 26) - too -

The strands produced with this formulation showed a high level of degradation and low expansion even with the addition of binder. Totally stable extruded product outflow without major variations. Strand formation with a medium amount of flakes (standard for the process). Apparent humidity of the product around 12%.

Example 2

In this example, increasing the level of botanical material (in this case tobacco) in the aerosol-generating material was investigated. Using the formulation set out below, is was possible to produce an aerosol-generating material comprising 74% tobacco. This material is referred to as T2.

In order to increase the level of tobacco in the material, it would to be advantageous to increase the level of tobacco material by reducing the proportion of the binder (starch) and cellulose fibre in the material. Altering the formulation in this way was found to provide an improved aerosol-generating material.

Advantages in the method of production of an aerosol-generating material from the T2 formulation were found to be obtained using the following operating parameters. In particular, increased pressure of the expanders and hydraulic system, and increased temperature were found to be advantageous:

SUBSTITUTE SHEET (RULE 26)

The resulting aerosol generating material had the following properties: Significant improvement in the process and in the product due to the installation of a steam preheating system. The preheating of the extruder allowed the thermochemical activation of the binder used in T2-T4 trials, which provided physical alteration of the filaments of trials T2, T3 and T4. The percentage of starch in the original formulation (12%) caused expansion of the filaments above the desirable limit, generating operational difficulties and obstruction at the exit of the extruder. Due to the problems presented, the T2 formulation was modified and some components had their percentage changed (starch was reduced from 12% to 5.5%). After formulation adjustment, the initial process did not present problems for filament formation. Process water flow changed during production due to glycerol application. Extruded product output flow without significant variations throughout production.

The filaments produced have moderate expansion and high density. Apparent humidity of the product around 12%. Damage index around 49% for 106kg batch.

SUBSTITUTE SHEET (RULE 26) Example

In this example, the effect of increasing the proportion of botanical material (in this case tobacco) present in the form of small particles (i.e. fines and dust which have a particle size of less than 0.5 mm) was investigated. The initial formulation, referred to as T3, was as shown in the table below. A good aerosol generating material was found to be produced using the following adjusted formulation: Specifically, in this formulation, compared to the T2 formulation, the level of botanical material (tobacco) in the form of fibre may be replaced by botanical material (tobacco) in the form of small particles (i.e. fines and dust) by increasing the level of cellulose fibre and total binder (starch and xanthan gum) used. Altering the formulation in this way was found to provide an improved aerosolgenerating material.

Advantages in the method of production of an aerosol-generating material using the T3 formulation were found to be obtained using the following operating parameters. In particular, the pressure of the first expander was increased and the pressure of the second expander was decreased relative to the pressures used in relation to both the Ti and T2 formulations:

SUBSTITUTE SHEET (RULE 26)

The resulting aerosol generating material had the following properties: The percentage of starch was reduced from 8% to 2.5% as a result of what happened in the previous test (T2), to maintain the total formulation, the same percentage of tobacco powder was added. The percentage of Xanthan Gum was also reduced from 4% to 2.5%. Even with this reduction, the filaments produced present great resistance, making cutting difficult and causing tangles at the exit of the extruder. Totally stable extruded product outflow without major variations. Filament formation with a medium amount of flakes (standard for the process). Apparent humidity of the product around 13%. Damage index around 79% for 120kg batch.

Example 4 In this example, the effect of using a different binder was investigated. This material is referred to as T4. The initial formulation was as shown in the table below. A good aerosol generating material was found to be produced using the following adjusted formulation:

SUBSTITUTE SHEET (RULE 26)

Like with T3, an improved aerosol-generating material was found to be produced by reducing the level of botanical material (tobacco) present in the form of fibre, and by increasing the level of cellulose fibre and total binder used.

Advantages in the method of production of an aerosol-generating material using the T4 formulation were found to be obtained using the following operating parameters. In general the optimal parameters were found to be broadly similar to those used in relation to the Ti formulation:

The resulting aerosol generating material had the following properties:

SUBSTITUTE SHEET (RULE 26)

As with the previous alternatives, the percentage of starch was reduced from 8% to 2.5% and the same percentage of tobacco powder was added. As a result of previous tests, the percentage of guar gum was also reduced in order to adjust the strength of the product to an adequate level. The strands produced with the T4 formulation showed excellent flexibility and adequate resistance to the process. Totally stable extruded product outflow without major variations. Filament formation with a medium amount of flakes (standard for the process). Apparent humidity of the product around 13%. Using this combination of process parameters and formulation, an aerosol generating material was produced having improved thickness, light weight, resistance to breakage, smoother surface, and reduced density in comparison with Ti, T2 and T3.

The material produced from the T4 formulation showed excellent flexibility and adequate resistance to the process. The extruded product outflow showed excellent stability without major variations.

Example

In this example, the effect of cellulose fibre was investigated. Materials were produced comprising cellulose fibre or an alternative fibrous material, in this case, tobacco fibre.

The materials comprising cellulose fibre were found to have a higher filling value than those comprising alternative fibrous material.

The materials comprising cellulose fibre were also found to have a significantly lower density than those comprising alternative fibrous material. Specifically, the density of

SUBSTITUTE SHEET (RULE 26) - io6 - the materials comprising cellulose fibre was found to be 70-80% of the density of the corresponding materials comprising alternative fibrous material.

The materials comprising cellulose fibre were also found to carry a greater level of aerosol forming material than those comprising alternative fibrous material.

In addition, the materials comprising cellulose fibre were found to be significantly better in terms of process performance due to being thicker, lighter, more resistant to fracture, smoother, and having a greater volume.

Example 6

In this example, the effect of different binders was investigated. Materials were produced comprising various different binders as indicated in the table below.

The materials comprising xanthan gum were found to have a higher filling value than those comprising alternative binders. The materials comprising CMC or HPC were found to have the next highest filling values. The materials comprising xanthan gum were also found to have a lower density than those comprising alternative binders. The materials comprising CMC or guar gum were found to have the next lowest densities. Materials comprising HPC were found to have the highest density. The materials comprising CMC were found to carry a greater level of aerosol forming material than those comprising alternative fibrous material. The materials comprising

SUBSTITUTE SHEET (RULE 26) guar gum or xanthan gum were found to have the next lowest densities, followed by materials comprising starch.

The materials comprising xanthan gum were found to have the longest strands, followed by materials comprising CMC or starch.

The materials comprising CMC were found to be better than materials comprising other binders in terms of process performance due to being thicker, lighter, more resistant to fracture, smoother, and having a greater volume. The materials comprising guar gum were found to be the next best, followed by materials comprising HPC or starch.

Example 7

In this example, aerosol-generating materials comprising botanical material consisting of mint powder, produced from mint leaf and mint stem material that had been dried and milled, were produced.

The mint material had the following particle size distribution: The moisture content of the mint material used was 5.76%.

The initial formulation was based on the preferred T4 formulation, comprising guar gum. This formulation was referred to as T7. The aerosol-generating material was found to be improved by replacing a proportion of the mint powder (equating to 4% of the total formulation) with cellulose fibre. This formulation was referred to as T9.

SUBSTITUTE SHEET (RULE 26) When further amounts of mint material were replaced with cellulose fibre it was found to be advantageous to increase the total level of binder in the formulation. This formulation was referred to as T14. The formulations of the T7, T9, and T14 materials are shown below:

The following operating parameters were found to be optimal in the production of the T14 material:

The resulting aerosol generating material had the following properties:

SUBSTITUTE SHEET (RULE 26)

The T14 material had a wet bulk density of 114 kg/m3.

Nicotine was added to the T14 material at three different levels: 0.5% (w/w), (0.5 g Nic/ 100g Fibex formulation); 1% (w/w), (1.0 g Nic/ 100g Fibex formulation) and 3%(w/w), (3.0g Nic/ioog Fibex formulation.

S(-)Nicotine analytical standard grade (enantiomeric purity >99%) was solubilized in ethanol (Base Nic solution = 3% w/w). From this base solution, were applied different amount using a spray to achieve 0.5%, 1% and 3% (w/w) in the final formulation.

The Nicotine content in the final material was determined by GC-FID analytical methodology used for quantification of Nicotine and other secondary alkaloids in tobacco.

Nicotine recovery (%) was determined as (Concentration determined by GC-FID/ Concentration applied in Fibex)*ioo.

The results were as follows:

Example 8

In this example, an aerosol-generating material comprising botanical material consisting of eucalyptus powder was produced.

SUBSTITUTE SHEET (RULE 26) The eucalyptus material was dried and milled, and had the following particle size distribution: The moisture content of the eucalyptus material used was 10.38%.

The formulation was based on the T4 formulation, and was referred to as T8, as shown below:

The following operating parameters were found to be optimal in the production of the T8 material. The expander pressures are the same as those used in relation to the T4 formulation, but, like with the use of mint, it was found to be advantageous to reduce the water flow rate and the raw material flow rate compared to the production of the tobacco materials. The parameters were as follows:

SUBSTITUTE SHEET (RULE 26)

The resulting aerosol generating material had the following properties: The material had a wet bulk density of 70 kg/ m³.

Nicotine was added to the T8 material as discussed above in Example 7. The results were as follows:

Example Q

In this example, an aerosol-generating material comprising botanical material consisting of cinnamon powder was produced.

SUBSTITUTE SHEET (RULE 26) The cinnamon material was dried and milled, and had the following particle size distribution: The moisture content of the cinnamon material used was 14.77%.

The formulation was based on the tobacco-containing T4 formulation, and was referred to as T12, as shown below:

The following operating parameters were found to be optimal in the production of the T12 material.

SUBSTITUTE SHEET (RULE 26)

The resulting aerosol generating material had the following properties: The material had a wet bulk density of 103 kg/ m3.

Example 10

In this example, an aerosol-generating material comprising botanical material consisting of lavender was produced.

The lavender material was dried and milled, and had the following particle size distribution: The moisture content of the lavender material used was 13.75%.

The formulation was based on the T4 formulation, and was referred to as T13, as shown below:

SUBSTITUTE SHEET (RULE 26)

The following operating parameters were found to be optimal in the production of the T13 material:

The resulting aerosol generating material had the following properties: The material had a wet bulk density of 83 kg/ m3.

SUBSTITUTE SHEET (RULE 26) Example n

In this example, an aerosol-generating material comprising botanical material consisting of clove was produced. The clove material was dried and milled, and had the following particle size distribution:

The moisture content of the clove material used was 23.36%.

The initial formulation was based on the T4 formulation, but the clove content was reduced, and to compensate, the levels of cellulose fibre and total binder were increased. This formulation was referred to as T10. An improved formulation was found to be produced by further reducing the clove content, compensated, by further increased levels of cellulose fibre and total binder. This formulation was referred to as

T16, The T10 and T16 formulations are shown below: The following operating parameters were found to be optimal in the production of the

T16 material:

SUBSTITUTE SHEET (RULE 26)

The resulting aerosol generating material had the following properties: The T16 material had a wet bulk density of 95 kg/ m3.

Example 12

In this example, an aerosol-generating material comprising botanical material consisting of rooibos was produced.

Three formulations were produced, with the following formulations:

SUBSTITUTE SHEET (RULE 26)

The following operating parameters were found to be optimal in the production of the rooibos materials:

The resulting aerosol generating materials had the following properties:

Example 13 In this example, the small particle content of the materials was examined by sieving, as a measure of brittleness.

SUBSTITUTE SHEET (RULE 26)

Compared to the material comprising tobacco (T4), the aerosol generating materials comprising non-tobacco botanical material had a significantly lower content of small particles, reflecting less brittle strands.

Example 14

In Example 5, materials comprising cellulose fibre were found to have a higher filling value than those comprising alternative fibrous material, and in Example 6, the use of different binders was found to affect the filling value. In this example, the effect of the nature and content of the tobacco botanical material and aerosol forming material on the filling value was investigated.

In addition to materials T20-T28 detailed in Examples 5 and 6, materials T18 and T19 were investigated.

The resulting aerosol generating materials had the following properties:

SUBSTITUTE SHEET (RULE 26)

A strong correlation was found between the aerosol forming material content of the initial formulation and the filling value of the resulting material, wherein materials having a higher filling were found to be produced when the formulation had a lower level of aerosol forming material.

On average, materials produced from a formulation comprising 5% aerosol forming material had a 23% greater filling value than materials produced from a formulation comprising 15% aerosol forming material.

Example i

In this example, the quality of the materials was assessed.

Materials were given a “quality score”. The quality score is a single value produced by combining values obtained from individual assessments of the thickness, lightness, resistance, surface smoothness, and volume of the materials. Higher quality score values indicate better performance in subsequence processing and use of the material.

SUBSTITUTE SHEET (RULE 26)

The factors that were found to most significantly influence the filling value and/or quality score of the material were found to be:

Content of aerosol forming material in the initial formulation (5% glycerol provided the greatest filling value and quality score);

The inclusion of fibre in the formulation (and in particular cellulose fibre);

- The nature of the binder used (CMC was found to provide the most significant combined positive effect on the filling value and quality score). Both filling value and quality score were found to be maximised when the cut speed (i.e. the rotation in rpm of the cone) and cut pressure (i.e. the pressure of the hydraulic system) were at substantially maximum levels, specifically between 90-100% of the maximum, such as 95%. The maximum speed of rotation of the cone is about 850 rpm, and the optimum speed of rotation of the cone was found to be about 770-850 rpm, such as about 810 rpm. The maximum pressure of the hydraulic system is about 150 bar, and the optimum pressure was found to be 135-150 bar, such as about 142 bar.

In contrast, both filling value and quality score were found to be maximised when the feeding rate of the material (i.e. the rotation in rpm of the feed screw) was significantly lower than the maximal level, specifically between 30-50% of the maximum, such as 40%. The maximum speed of rotation of the feed screw is about 30 rpm, and the optimum speed of rotation of the feed screw was found to be about 9-15 rpm, such as about 12 rpm. Example 16

Based on the findings in Example 15 using tobacco-based formulations, materials comprising non-tobacco botanical material were produced to test the effects of the content aerosol forming material and binder in the formulation, and the processing parameters, on the filling value and quality score of the resulting material.

Materials comprising non-tobacco botanical materials were produced comprising a binder comprising CMC, and aerosol forming material comprising either 5% or 15% aerosol forming material (AFM), using processing parameters comprising 40% of the

SUBSTITUTE SHEET (RULE 26) maximal feeding rate (i.e. feed screw rotation at about 12 rpm), 95% or the maximal cut pressure (i.e. hydraulic system pressure at about 142 bar), and 95% of the maximal cut speed (i.e. cone rotation at about 810 rpm). The formulations and resulting filling value and quality score for materials comprising different non-tobacco botanical materials are set out below.

Mint:

Eucalyptus:

Cinnamon:

SUBSTITUTE SHEET (RULE 26)

Lavender:

Clove:

Average:

SUBSTITUTE SHEET (RULE 26) Using CMC as the binder was found to result in a 23% increase in the filling value.

Using CMC and 5% aerosol forming material was found to result in a 52% increase in the filling value.

Rooibos:

Similar experiments were also performed using rooibos botanical material. Using a binder comprising guar gum and starch increased the filling value from 40.8 citf/ 10g to 46 cm³/ 10g, and also significantly improved the quality score.

Reducing the level of aerosol forming material from 15% to 5% further increased the filling value, to 53 cnU/iog. In summary, a filling value of greater than 40 cm 10g was obtainable for all nontobacco botanical materials tested. The use of CMC binder and/or reduced aerosol forming material did not significantly affect the quality score of the material, which was on average around 36-40 in each case. Materials having an average filling value of 42 cm³/ 10g were obtained from formulations comprising non-tobacco botanical material and 15% aerosol forming material. These materials were considered to be “high aerosol forming materials”.

SUBSTITUTE SHEET (RULE 26) Materials having an average filling value of 49 cm3/iog were obtained from formulations comprising non-tobacco botanical material and 5% aerosol forming material. These materials were considered to be “high filling value materials”. For reference, the filling value of an equivalent reconstituted tobacco paper material is typically in the region of 44 cm3/iog. Thus, the disclosed process allows the production of aerosol generating materials from non-tobacco botanical materials that have a filling value similar to, or greater than, that of equivalent reconstituted paper materials. Example 17

In the example, the flavour and aroma generated by the aerosol generating materials comprising non-tobacco botanical materials was investigated.

Formulations for the production of the disclosed aerosol generating materials for the analysis of the aroma and flavour compounds provided by the materials in use are set out below. For comparison, extruded sheet materials were also produced (labelled “Extruded Sheet”) using the formulations indicated below.

Mint:

Eucalyptus:

SUBSTITUTE SHEET (RULE 26)

Cinnamon:

Lavender:

Clove:

SUBSTITUTE SHEET (RULE 26) The results of the analysis of the flavour and aroma compounds are set out below. The odour activity values (OAVs) were determined as indicated. OAVs represent the contribution of a single odorant to the overall odour of the material. The main odourproviding substance of a material is not the substance with the highest concentration but with the highest OAV. The OAV is the mass concentration of the substance divided by the odour threshold of the substance. Thus, the lower the odour threshold of the substance, the more likely it is contribute to the odour of the material. The OAV is a dimensionless factor. Mint

The total aroma amount potential was found to be similar between the T14 material and the extruded sheet upon heating of the material. For both materials, the emissions are characterized mainly for Woody sector arena.

Eucalyptus

The total aroma amount potential was found to be slightly higher in the extruded sheet that the T8 material upon heating of the material. For both materials, the emissions are characterized mainly for Green sector arena.

SUBSTITUTE SHEET (RULE 26) Cinnamon

The total aroma amount potential was found to be similar between the T12 material and the extruded sheet upon heating of the material. For both materials, the emissions are characterized mainly for Spicy sector arena.

Lavender The total aroma amount potential was found to be significantly higher in the T13 material than the extruded sheet upon heating of the material. For both materials, the emissions are characterized mainly for Floral sector arena.

Clove

SUBSTITUTE SHEET (RULE 26)

The total aroma amount potential was found to be similar between the T16 material and the extruded sheet upon heating of the material. For both materials, the emissions are characterized mainly for Spicy and Woody sector arena.

Similar experiments were also performed using rooibos botanical material. The total aroma amount potential was found to be similar between the rooibos material produced by the disclosed method and an extruded sheet produced from a similar formulation upon heating of the material. For both materials, the emissions are characterized mainly for Woody sector arena. In terms of secondary arenas, Creamy is found only in the extruded sheet while Floral is found only in the material produced by the disclosed method. Guaiacol and 2-Methoxy-4-vinylphenol could be found in similar concentration in the extruded sheet and the material produced by the disclosed method.

In summary, the aroma potential for each of the materials produced by the disclosed method is generally at least equivalent to that of a corresponding extruded sheet material. The fact that the different materials produced by the disclosed method, comprising different non-tobacco botanical materials, generate aromas that are characterized mainly for different sector arenas highlights that the materials may be combined to provide new and complex aroma profiles from natural sources. Example 17

In order to test the materials produced using the disclosed method in articles in use with non-combustible aerosol provision devices, test articles were prepared.

The aerosol generating material of the test articles consisted of either a rooibos aerosol generating material produced by the disclosed method (formulation T37.4 (Group A in Figure 5) or T37.6 (Group B)) or a reconstituted paper sheet material produced from a similar formulation (Group C).

SUBSTITUTE SHEET (RULE 26) All of the aerosol generating materials were injected with nicotine, acid, flavour, menthol and capsules to match the material of a commercial product. The articles were then used in a commercial Gio Hyper device. The aerosols produced were tested and given an intensity rating from 1-10 for the parameters indicated in Figure 5 (from left to right: hot puff; ISS (first three puffs - highest); Initial flavour intensity (first three puffs

- average); impact; irritation; aerosol body; visible aerosol; botanical flavour intensity; flavour consistency; aerosol consistency; off notes; and draw effort).

The results are shown in Figure 5. Each group consists of 11 repeats. No significant differences between the groups were observed.

Overall, 45% of consumers preferred the Group A article, 22% of consumers preferred the Group B article; and 33% of consumers preferred the Group C article. The results indicate that aerosol generating materials may be produced from nontobacco botanical materials that provide similar properties in use to those of extruded sheet materials.

In order to address various issues and advance the art, the entirety of this disclosure shows by way of illustration various embodiments in which the claimed invention(s) maybe practiced and provide for superior manufacture of aerosol generating material. The advantages and features of the disclosure are of a representative sample of embodiments only, and are not exhaustive and/or exclusive. They are presented only to assist in understanding and teach the claimed features. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects of the disclosure are not to be considered limitations on the disclosure as defined by the claims or limitations on equivalents to the claims, and that other embodiments maybe utilised and modifications maybe made without departing from the scope and/or spirit of the disclosure. Various embodiments may suitably comprise, consist of, or consist essentially of, various combinations of the disclosed elements, components, features, parts, steps, means, etc. In addition, the disclosure includes other inventions not presently claimed, but which may be claimed in future.

SUBSTITUTE SHEET (RULE 26)

Claims

1. A method of manufacturing aerosol generating material, the method comprising: providing an initial material comprising at least 20%, by mass, of particulate non-tobacco botanical material; and processing the initial material by subjecting the initial material to an increased mechanical pressure to produce the aerosol generating material; further comprising at least one of: applying an additive selected from an aerosol forming material, an active substance, and a binder to the initial material prior to or while subjecting the initial material to the increased mechanical pressure; and applying an additive selected from an aerosol forming material, an active substance, and a binder to the aerosol-generating material after subjecting the initial material to the increased mechanical pressure.

2. A method according to claim 1, wherein the initial material comprises less than 60%, by mass, of tobacco material.

3. A method according to claim 1 or 2, wherein the initial material comprises more than 30%, by mass, of particulate non-tobacco botanical material.

4. A method according to any one of claims 1 to 3, wherein the aerosol generating material contains no tobacco material.

5. A method according to any one of claims 1 to 4, wherein the particulate non- tobacco botanical material is a material derived from species which are members of the Asteracae family, the Fabaceae family, the Myrtaceae family, Apiaceae family, Camellia taliensis, the Solanaceae family, the Brassicaceae family, the Caricaceae family, the Asclepiadaceae family, the Equisetaceae family, the Oleaceae family, the Lamiaceae family, and tisanes.

6. A method according to any one of claims 1 to 5, wherein the particulate non- tobacco botanical material is selected from the Matricaria species, such as chamomile; the Pimpinella anisum species, such as anise; the Foeniculum vulgare species, such as fennel; jasmine; lavender; cloves; eucalyptus, and the species Aspalathus linearis, such

SUBSTITUTE SHEET (RULE 26) as rooibos.

7. A method according to any one of claims 1 to 6, wherein the particulate nontobacco botanical material comprises mint, eucalyptus, lavender, ginger, cinnamon, rooibos, and/or clove material.

8. A method according to any one of claims 1 to 7, wherein the initial material further comprises non-tobacco cellulose fibre.

9. A method according to claim 8, further comprising combining the botanical material with the non-tobacco cellulose fibre to provide the initial material, wherein the initial material comprises at least 50%, by mass, of the particulate non-tobacco botanical material.

10. A method according to claim 8 or 9, further comprising: processing the initial material by: setting the initial material to a predefined moisture content; subjecting the initial material to an increase in temperature; and subjecting the initial material to the increased pressure in order to bind the particulate non-tobacco botanical material to the non-tobacco cellulose fibre to produce the aerosol generating material.

11. A method according to any one of claims 8 to 10, wherein the particulate non- tobacco botanical material and the non-tobacco cellulose fibre are each pre-sized and have particle size distributions that substantially overlap or correspond in size.

12. A method of manufacturing aerosol generating material, the method comprising: providing an initial material comprising particulate tobacco botanical material and non-tobacco cellulose fibre, wherein the initial material comprises at least 20%, by mass, of particulate tobacco botanical material; and processing the initial material by subjecting the initial material an increased mechanical pressure to produce the aerosol generating material; further comprising at least one of:

SUBSTITUTE SHEET (RULE 26) applying an additive selected from an aerosol forming material, an active substance and a binder to the initial material prior to or while subjecting the initial material to the increased mechanical pressure; and applying an additive selected from an aerosol forming material, an active substance and a binder to the aerosol-generating material after subjecting the initial material to the increased mechanical pressure.

13. A method according to claim 12, further comprising: processing the initial material by: setting the initial material to a predefined moisture content; subjecting the initial material to an increase in temperature; and subjecting the initial material to the increased pressure in order to bind the particulate tobacco botanical material to the non-tobacco cellulose fibre to produce the aerosol generating material.

14. A method according to any one of claims 8 to 13, wherein the initial material and/ or the aerosol generating material comprises at least 5%, by mass, of non-tobacco cellulose fibre.

15. A method according to any one of claims 8 to 14, wherein the non-tobacco cellulose fibre comprises or consists of wood pulp.

16. A method according to any one of claims 8 to 15, wherein the initial material comprises 5-20%, by mass, of non-tobacco cellulose fibre.

17. A method according to any one of claims 8 to 16, wherein the non-tobacco cellulose fibre is pre-sized and has a Dpgo value of between 130 micrometres and 200 micrometres, a Dpso value of between 50 micrometres and too micrometres, and a Dpio value of between 10 micrometres and 50 micrometres.

18. A method according to any one of claims 1 to 17, wherein the initial material and/ or the aerosol generating material comprise the aerosol forming material in an amount of 10-25% by mass.

SUBSTITUTE SHEET (RULE 26)

19- A method according to claim 18, wherein the initial material and/or the aerosol generating material comprise the aerosol forming material in an amount of 15-20% by mass.

20. A method according to any one of claims 1 to 19, wherein the aerosol forming material comprises glycerol, propylene glycol, or a mixture of glycerol and propylene glycol.

21. A method according to any one of claims 1 to 20, wherein the initial material and/ or the aerosol generating material comprise the binder in an amount of up to 25% by mass.

22. A method according to any one of claims 1 to 21, wherein the binder comprises carboxymethyl cellulose (CMC), starch, guar gum, xanthan gum, acacia gum and/or hydroxypropyl cellulose (HPC).

23. A method according to any one of claims 1 to 22, wherein the active substance is selected from nutraceuticals, nootropics and psychoactives.

24. A method according to any one of claims 1 to 23, wherein the active substance comprises nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations, or one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical.

25. A method according to any one of claims 1 to 24, wherein the active substance comprises nicotine or a nicotine salt.

26. A method according to claim 25, wherein the initial material and/ or the aerosol generating material comprise nicotine in an amount of up to 3%, by weight.

27. A method according to any one of claims 1 to 26, wherein the initial material and/ or the aerosol generating material further comprises an acid.

28. A method according to claim 27, wherein the initial material and/ or the aerosol generating material comprises an acid in an amount of from about 0.1% to about 5% by weight.

SUBSTITUTE SHEET (RULE 26)

29. A method according to claim 27 or 28, wherein the acid comprises one or more acids selected from lactic acid, benzoic acid, citric acid, levulinic acid, 2-methylbutyric acid, and 2-methylvaleric acid.

30. A method according to any one of claims 1 to 29, wherein the aerosol generating material has a Dpgo value of between 1.2mm and 6.0mm, a Dpso value of between 1.1mm and 2.4mm, and a Dpio value of between 0.2mm and 1.5mm.

31. A method according to any one of claims 1 to 30, wherein the aerosol generating material has a fill value of greater than 25 cm3/iog.

32. A method according to any one of claims 1 to 31, wherein processing the initial material comprises conveying the initial material through a conveyor which builds up a mechanical pressure, wherein the conveyer is operated at a throughput of 25-75 kg/hr.

33. A method according to any one of claims 1 to 32, wherein processing the initial material comprises the use of a water flow rate of less than 12 L/h.

34. A method according to any one of claims 1 to 33, wherein processing the initial material comprises pressurising the initial material to a pressure in the range of 15-35 bar.

35. A method according to any one of claims 1 to 34, comprising feeding the processed material through a shearing gap, wherein the shearing gap is arranged between shearing surfaces, wherein a rotatable shearing member comprises one of the shearing surfaces, and wherein the method comprises rotating the shearing member at an angular velocity of 500-850 rpm.

36. A method according to any one of claims 1 to 35, comprising applying the aerosol forming material and the active substance to the initial material prior to or while subjecting the initial material to the increased mechanical pressure.

37. A method according to any one of claims 1 to 36, comprising applying the aerosol forming material and the active substance to the aerosol-generating material after subjecting the initial material to the increased mechanical pressure.

SUBSTITUTE SHEET (RULE 26)

38. A method according to any one of claims 1-37, wherein the aerosol generating material is a non-continuous aerosol generating material.

39. An aerosol generating material, comprising: at least 20%, by mass, of particulate botanical material; non-tobacco cellulose fibre; and at least one additive selected from: an aerosol forming material; an active substance; and a binder.

40. An aerosol generating material according to claim 39, wherein the particulate botanical material comprises particulate tobacco material or particulate non-tobacco material or a combination thereof.

41. An aerosol generating material that is obtained or obtainable by the method of any one of claims 1 to 38.

42. An aerosol generating material according to any one of claims 39-41, wherein the aerosol generating material is a non-continuous aerosol generating material.

43. A component for a delivery system, wherein the component comprises the aerosol generating material of any one of claims 39-41.

44. A component according to claim 43, wherein the component is for an aerosol provision system.

45. A product comprising a component according to claim 43 or claim 44.

46. An article for use in or as an aerosol provision system, the article comprising a component according to claim 43 or claim 44.

47. An article comprising an aerosol generating material produced in accordance with the method of any one of claims 1 to 38.

SUBSTITUTE SHEET (RULE 26)

48. Use of an aerosol-generating material as claimed in any one of claims 39-41 in an article for use in an aerosol provision system.

49. An article for use in or as an aerosol provision system comprising an aerosol- generating material as claimed in any one of claims 39-41.

50. A system comprising an aerosol-generating material as claimed in any one of claims 39-41 and a device arranged to heat the aerosol-generating material and generate an aerosol from the aerosol-generating material.

SUBSTITUTE SHEET (RULE 26)