JP6042210B2 - Tobacco products and manufacturing methods - Google Patents

Description

  The present invention relates to a product made or derived from tobacco or otherwise incorporating tobacco, which is intended for human consumption.

  Cigarettes, cigars and pipes are common smoking articles that use various forms of tobacco. Such smoking articles are used by heating or burning tobacco, and smokers can inhale aerosols (eg, smoke) into the lungs. You can also enjoy tobacco in the so-called “smokeless” form. A particularly popular smokeless tobacco product is used by inserting some form of processed tobacco or tobacco-containing formulation into the user's mouth.

  Various types of smokeless tobacco products are available from Schwartz U.S. Pat. S. Pat. No. 1,376,586; Levi 3,696,917; Pittman et al. 4,513,756; Sensabaugh, Jr. 4,528, 993; Story et al. 4,624,269; Townsend 4,987,907; Slinkle, III et al. 5,092,352; and White et al. 5,387,416; Strickland et al. U . S. Pat. Appl. Pub. No. 2005/0444521; Arnarp et al. WO 04/095959; Atchley et al. WO 05/063060; Engstrom WO 05/004480; Bjorholm WO 05/016036; and Quinter et al. WO 05/041699, each of these references. Which is incorporated herein by reference. For example, U.S. Pat. S. Pat. No. 6,953,040 and Atchley et al., 7,032,601; S. Pat. Appl. Pub. No. 2002/0162562; Williams 2002/0162563; Atchley et al. 2003/0070687; Williams 2004/0020503; Breskin et al. 2005/0178398; Strickland et al. 2006/0191548; Holton, Jr. Et al., 2007/0062549; Holton, Jr. 2007/0186941; Strickland et al. 2007/0186942; Dube et al. 2008/0029110; Robinson et al. 2008/0029116; Mua et al. 2008/0029117; Robinson et al. 2008/0173317; Neilsen et al. 2009/0095313 and Kumar et al., 2009/02938989; and Chen et al., US patent application Ser. No. 12 / 476,621, filed Jun. 2, 2009, smokeless tobacco formulations of the type, materials and processing. See also methodology (each of these references is incorporated herein by reference).

  One type of smokeless tobacco product is called “sniff tobacco”. Snuff tobacco is generally formulated in a “wet” or “dry” form. Representative types of wet snuff, commonly referred to as “Sunus”, in Europe, especially in Sweden, by Swedish Match AB, Fiedler & Lundgren AB, Gustavus AB, Skandavisk Tobskmpagni A and B Manufactured through the company. Sunus products available in the United States are R.D. under the trade names Camel Snus Frost, Camel Snus Original and Camel Snus Spice. J. et al. Commercially available from Reynolds Tobacco Company. Representative smokeless tobacco products are traded under the trade name Olive Twist by House of Oliver Twist A / S; under the tradenames Copenhagen, Skial, SkialDry, Rooster, Red Seal, Husky and Revel. S. Smokeless Tobacco Co. By Philip Morris USA under the trade name “taboka”; L. P. Is also commercially available. See, for example, Bryzgalov et al. See also 1N1800 Life Cycle Assessment, Comparable Life Cycle Assessment of General Rose and Portion Snus (2005). In addition, certain quality standards related to sonus production have been established as so-called “GothiaTek” standards.

  It would be desirable to provide an enjoyable form of tobacco products efficiently and effectively and to provide a method for preparing molded or extruded type tobacco products.

US Pat. No. 1,376,586 US Pat. No. 3,696,917 US Pat. No. 4,513,756 US Pat. No. 4,528,993 US Pat. No. 4,624,269 US Pat. No. 4,987,907 US Pat. No. 5,092,352 US Pat. No. 5,387,416 US Patent Application Publication No. 2005/0244521 International Publication No. 04/095959 International Publication No. 05/063060 International Publication No. 05/004480 International Publication No. 05/016036 International Publication No. 05/041699 US Pat. No. 6,953,040 US Pat. No. 7,032,601 US Patent Application Publication No. 2002/0162562 US Patent Application Publication No. 2002/0162563 US Patent Application Publication No. 2003/0070687 US Patent Application Publication No. 2004/0020503 US Patent Application Publication No. 2005/0178398 US Patent Application Publication No. 2006/0191548 US Patent Application Publication No. 2007/0062549 US Patent Application Publication No. 2007/0186941 US Patent Application Publication No. 2007/0186942 US Patent Application Publication No. 2008/0029110 US Patent Application Publication No. 2008/0029116 US Patent Application Publication No. 2008/0029117 US Patent Application Publication No. 2008/0173317 US Patent Application Publication No. 2008/0209586 US Patent Application Publication No. 2009/0095313 US Patent Application Publication No. 2009/0298989 US Patent Application Serial No. 12 / 476,621

Bryzgalov et al. , 1N1800 Life Cycle Assessment, Comparable Life Cycle Assessment of General Loose and Portion Snus (2005)

  The present invention relates to a product made or derived from tobacco or otherwise incorporating tobacco, which is intended for human consumption. Of particular interest are tobacco products, compositions or formulations and methods of providing, producing or assembling these tobacco products, compositions or formulations. Certain highly preferred tobacco products can be used in so-called smokeless form and can be formulated and / or shaped to be suitable for insertion into the mouth of smokeless tobacco users.

  The tobacco product incorporates a binder system. That is, tobacco material (which can have various forms and can consist of various types of tobacco) and other suitable materials during production or assembly are processed in the presence of a binder system. Of particular interest are binder systems that have or exhibit thermoplastic properties, thermoplastic properties or thermoplastic behavior. The binder system may incorporate at least one type of binder that exhibits thermoplastic properties, thermoplastic properties or thermoplastic behavior (eg, the binder comprises at least one thermoplastic polymer material). obtain.). In addition, the binder system may incorporate a material or material to produce a binder that exhibits thermoplastic properties (eg, the binder is combined with at least one thermoplastic in combination with a plasticizer). It can be made of a binder.) In certain embodiments, the thermoplastic binder system may consist of at least one thermoplastic polymer material and a thermoplastic binder in combination with at least one plasticizer. In certain highly preferred embodiments, the amount of thermoplastic polymer material used to produce a representative processed tobacco product can be no more than about 20 percent of the final molded product or formulation, on a dry weight basis. Accordingly, the present invention, in one aspect, relates to a tobacco product in a form suitable for insertion into a user's mouth, and includes tobacco and a thermoplastic binder system, the amount of the thermoplastic binder system being the amount of the tobacco product. It is present in an amount less than about 30 weight percent of the dry weight. Still other preferred tobacco products may incorporate binder systems and plasticizer blends. The plasticizer blend can be premixed, heated and added to the tobacco material and / or binder system to produce a chewable tobacco product.

  Certain preferred methods for producing, producing or assembling these tobacco products include contacting tobacco with other desired materials in the presence of a binder system, and the resulting mixture in a certain shape. With the step of forming. In certain highly preferred embodiments, the method includes extruding the mixture into a strip, sheet, rod, tube or other desired shape (or otherwise physically shaping, such as by molding or casting). ) With process steps. The mixing of the tobacco formulation involves contacting the tobacco to be processed with a binder system that exhibits thermoplastic properties. Control processing conditions associated with the production of tobacco products (eg, temperature and / or pressure experienced by mixing during processing conditions, moisture and / or other solvent content of the processed mixture, mixing conditions, or the like By controlling things (to control) efficiently and effectively produce tobacco products with the desired physical and sensory characteristics. Of particular interest is the use of relatively small amounts of processing conditions, most preferably involving exposing the tobacco formulation to temperatures below about 100 ° C. during processing conditions (eg, those experienced during extrusion). Processing conditions with the use of a binder that can be exhibited, exhibiting desirable thermoplastic behavior at processing conditions of less than about 100 ° C. (and thus can act to provide good physical binding properties to molded tobacco products) Processing conditions involving the use of binders and processing conditions involving the use of relatively small to moderate amounts of liquid processing aids (eg water or other liquid carriers). Accordingly, the present invention, in one aspect, relates to a method for producing a smokeless tobacco product, the method comprising contacting a tobacco material and a thermoplastic binder system to form a mixture; subjecting the mixture to an elevated temperature; Forming the mixture into the desired shape of the tobacco product; and cooling the tobacco product. The method in another embodiment can include mixing the plasticizer blend, heating the plasticizer blend, and then contacting the plasticizer blend with a mixture of tobacco material and thermoplastic binder system.

  As those skilled in the art will appreciate, many different embodiments of tobacco products and methods of manufacturing or assembling tobacco products are possible. Additional uses, advantages and features of the tobacco product and its method of manufacture are set forth in the illustrative embodiments within the detailed description herein and will become more apparent to those skilled in the art upon subsequent verification. I will.

  The products, compositions, formulations and methods described herein may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, the disclosure is complete These embodiments are provided so that they will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. As used herein in the specification and in the claims, the singular forms “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise. Reference to “dry weight percent” or “dry weight base” refers to weight based on dry material (ie, all materials except water).

  The tobacco used as tobacco material for the preparation of tobacco products, compositions or formulations can vary. Tobacco includes: Fully cured tobacco, Burley tobacco, Sun cured tobacco (eg Oriental tobacco or Indian Karnur), Maryland tobacco, dark tobacco, dark fired tobacco, Indian air cured, dark air Cured (eg, passsanda, cubano, jatin and bezki tobacco) or light air cured (eg, North Wisconsin and galpoa tobacco) and Rustica tobacco , As well as other rare or special tobacco or even types of tobacco such as tobacco that is not fresh or cured. A description of the various types of tobacco, cultivation practices, harvest practices and curing practices can be found in Tobacco Production, Chemistry and Technology, Davis et al., Incorporated herein by reference. (Eds.) (1999). Sensabaugh, Jr. Et al. S. Patent No. 4,660,577; White et al. 5,387,416; and Dominguez et al. 6,730,832, Lawrence, Jr. U. S. Patent Appl. Pub. No. See also 2006/0037623 and Nielsen et al., PCT WO2008 / 103935, each of which is hereby incorporated by reference. Most preferably, the tobacco material is one that has been properly cured and aged. Particularly preferred techniques and conditions for curing flue-cured tobacco are described in Nestor et al., Which is incorporated herein by reference. , Beitage Tabakforsch. Int. , 20 (2003) 467-475 and Peele's U.S.A. S. Pat. No. 6,895,974. Representative techniques and conditions for air curing tobacco are described by Roton et al., Which is incorporated herein by reference. , Beitage Tabakforsch. Int. , 21 (2005) 305-320 and Staaf et al. , Beitage Tabakforsch. Int. , 21 (2005) 321-330. Certain types of rare or rare tobacco can be sun cured. Exemplary oriental tobaccos include katerini, prelip, komotini, xanthi, and yanbol tobacco. Tobacco compositions, including dark air cured tobacco, are described by Marshall et al., U.S. Pat. S. Patent Appl. Pub. No. 2008/0245377.

  Tobacco products may incorporate a single type of tobacco (eg, in the so-called “straight grade” form). For example, the tobacco may consist solely of flue-cured tobacco (eg, all of the cigarettes consist of flue-cured tobacco leaves or a mixture of flue-cured tobacco leaves and flue-cured tobacco stems). May consist of or be derived from either). Tobacco products may have a so-called “blend” form (although this form is most preferred). For example, the tobacco product can be a fluorinated burley (eg, Malawi burley tobacco) (eg, tobacco consisting of tobacco leaf or a mixture of tobacco leaf and tobacco stem or derived therefrom) and May contain a mixture of oriental tobacco parts or pieces. For example, a typical blend is about 30 to about 70 parts burley tobacco (eg, leaf blades or leaves and stems) and about 30 to about 70 parts fluid cured tobacco (eg, on a dry weight basis) , Stem, leaf blade, or leaf and stem). Other exemplary tobacco blends are about 75 parts full cured tobacco, about 15 parts burley tobacco and about 10 parts Oriental tobacco on a dry weight basis, or about 65 parts fluid cured tobacco, about 25 parts. Part burley tobacco and about 10 parts oriental tobacco; or about 65 parts flue-cured tobacco, about 10 parts burley tobacco and about 25 parts oriental tobacco. Other exemplary tobacco blends incorporate from about 20 to about 30 parts oriental tobacco and from about 70 to about 80 parts fully cured tobacco.

  Tobacco processed in accordance with the present invention is a pre-processed tobacco part or piece, a cured and aged tobacco essentially in the form of a natural leaf blade or stem, tobacco extract (eg, using water as a solvent). Extracted tobacco pulp, or a mixture of the foregoing (eg, a mixture of extracted tobacco pulp and granulated, cured and aged natural tobacco leaves, or granulated tobacco leaves and stems) And a mixture having an aqueous tobacco extract). Tobacco parts in tobacco products can be processed tobacco stems (eg, cut and rolled stems, cut and rolled and expanded stems or cut and expanded stems), or volume expanded tobacco (eg, dry ice expanded) It may have a processed form such as tobacco (expanded tobacco such as DIET). For example, de la Burde et al. S. Pat. No. 4,340,073; Guy et al. 5,259,403; and Pointdexter et al. 5,908,032; and Pointexter et al. S. Patent Appl. Pub. No. See the tobacco expansion method shown in 2004/0182404 (all of these references are hereby incorporated by reference). In addition, tobacco products can optionally incorporate fermented tobacco. See also the tobacco processing technology of the type shown in Atchley et al., PCT WO05 / 063060, which is incorporated herein by reference.

  The tobacco to be processed most preferably includes tobacco leaf or a mixture of tobacco leaf and stem. Tobacco mixtures that incorporate a significant amount of tobacco leaf relative to the tobacco stem are preferred. Most preferably, tobacco leaf blades and stems are cured and aged in unextracted form, i.e., with extractable parts (e.g. water-soluble parts) present in non-extractable parts (e.g. tobacco pulp). It is used in a manner equivalent to that of natural tobacco provided in the form.

  The processed tobacco can have a chopped form, a ground form, a granulated form, a particulate form or a powder form. The manner in which tobacco is provided in a finely divided or powder type form can vary. Preferably, tobacco parts or pieces are ground, pulverized, or pulverized into powder-type forms using equipment and techniques for grinding, pulverizing, or the like. Most preferably, the tobacco is relatively dry in form during grinding or milling using equipment such as a hammer mill, cutter head, air control mill or the like. For example, tobacco parts or pieces can be ground or pulverized when their moisture content is less than about 15 weight percent to less than about 5 weight percent.

  Most preferably, the tobacco to be processed can be used in the form of a part or piece having an average particle size smaller than that of the cut tobacco part or piece used in so-called “fine cut” tobacco products. Typically, the ultrafine tobacco particles or pieces can be sized to pass through a sieve of about 18 Tyler mesh, and can generally be sized to pass through a sieve of about 20 Tyler mesh, often about 50 Tyler. May be sized to pass through a sieve of mesh, often may be sized to pass through a sieve of about 60 Tyler mesh, may be sized to pass through a sieve of 100 Tyler mesh, and in addition, a sieve of 200 Tyler mesh The size may pass through. If desired, an air classifier can be used to reliably recover small size tobacco particles of the desired size or size range. In one embodiment, the tobacco material is in particulate form sized to pass 18 Tyler mesh but not 60 Tyler mesh. If desired, granulated tobacco pieces of different sizes may be mixed together. Ultrafine tobacco particles or pieces in some products or formulations have a particle size greater than -8 Tyler mesh, often -8 to +100 Tyler mesh, often -18 to +60 mesh. In other products or formulations, ultrafine tobacco particles or powders suitable for smokeless products described herein are smaller than −8 Tyler mesh, often +100 to +250 Tyler mesh, and often +120 to +280 Tyler mesh. May have a particle size of

  Tobacco extract can be used as a component of tobacco products. Tobacco extracts can be used in solid form (eg, spray dried or freeze dried form), in liquid form, in semi-solid form, or the like. Exemplary tobacco extracts and extraction techniques are described, for example, in Osborne, Jr. Et al. S. Pat. No. No. 4,150,677; Fagg et al. 4,967,771; Fagg et al. 5,005,593; Fagg 5,148,819; and Clapp et al. 5,435,325. All of the literature is hereby incorporated by reference. Various tobacco extracts and reconstitution methodologies are available from Fagg U.S. Pat. S. Pat. No. 5,065,775; Newton 5,360,022; and Fagg 5,131,414, all of which are hereby incorporated by reference. Munoz et al. S. Pat. No. See also the tobacco extraction processing methods shown in US Pat. No. 5,131,415 and Gonzalez-Parra 5,318,050, both of which are incorporated herein by reference.

  The tobacco material to be processed may optionally incorporate reconstituted tobacco, and therefore the reconstituted tobacco material component may be absent from the tobacco formulation being processed. However, suitable optional reconstituted tobacco processing techniques, such as papermaking techniques or casting type methods, can be used to produce such optional tobacco material components. See, for example, Tughan's U.S. Pat. S. Pat. No. 3,398,754; Mattina 3,847,164; Kite 4,131,117; Jenkins 4,270,552; Mattina 4,308,877; Kertissis 4,341,228; Gellaly 4,706,692; Thomasson 4,962,774; Clapp 4,941,484; Young 4,987,906; Brown 5,056,537; Son 5,143, Papermaking of the type shown in Brinkley et al. 5,159,942; Young 5,325,877; Brinkley 5,445,169; Young 5,501,237; Young 5,533,530 See how. See, for example, Hind U.S., incorporated herein by reference. S. Pat. No. Hind 3,399,454; Hind 3,483,874; Deszyck 3,760,815; Kertissis 4,674,519; Kiernan 4,972,854; Hickle 5, Young, 5,099,864; Jakob, 5,101,839; Hickle, 5,203,354; Lekwawa, 5,327,917; Young, 5,339,838; Jakob, 5,598, See 868; Young, 5,715,844; Gelatly, 5,724,998; and Kumar, 6,216,706; and EPO 565360; EPO 1053575 and PCT WO 98/01233. .

  If desired, prior to tobacco product preparation, parts or pieces of tobacco material may be irradiated, or these parts and pieces may be pasteurized, or otherwise subjected to a controlled heat treatment. Also good. In addition, if desired, after preparation of all or part of the tobacco formulation, the component materials may be irradiated, these component materials may be pasteurized, or otherwise subjected to controlled heat treatment. May be. For example, a formulation may be prepared, followed by irradiation or pasteurization, after which flavoring ingredients and other additional ingredients may be incorporated into the formulation. Alternatively, after processing the tobacco formulation (eg, after molding the extruded tobacco product, or subdividing the extruded product to the desired size to provide a separate container for the Snus type smokeless tobacco product, in a moisture permeable packet or pouch After being incorporated into) the tobacco product can be irradiated or pasteurized.

  The tobacco material can also be subjected to other types of pretreatment conditions prior to use in the process steps of the present invention. For example, the tobacco material can be treated to modify the physical or sensory properties of the tobacco material. In one respect, the tobacco material can be wetted or reordered. In another respect, the tobacco material can be pretreated by treatment involving the application of heat, steam, cooking or the like. In another respect, various additional ingredients, such as those of the types shown below, can be combined with the tobacco material during pretreatment processing conditions (eg, conditions involving heat treatment). In yet another aspect, tobacco material can be subjected to processing steps that involve the use of materials having acidic or basic properties. In yet another aspect, tobacco materials are prepared in the manner shown in Chenr et al., US patent application Ser. No. 12 / 476,621, filed Jun. 2, 2009, which is incorporated herein by reference. Can be processed.

  The tobacco material to be processed may be processed in combination with at least one additional component. For example, tobacco used in the manufacture of tobacco products can be processed with, blended with, blended with, and mixed with other materials or ingredients. For example, tobacco compositions may incorporate salts, sweeteners, binders, colorants, pH adjustors, buffers, fillers, flavoring agents, disintegration aids, antioxidants, humectants and preservatives. For example, White et al. S. Pat. No. 5,387,416; Strickland et al. S. Patent Appl. Pub. No. 2005/0244521; Dube et al. 2008/0029110; Kumar et al. 2009/0298989; Chen et al. US patent application Ser. No. 12 / 476,621 filed Jun. 2, 2009; and Quinter et al. See these representative ingredients, combinations of ingredients, the relative amounts of these ingredients and ingredients relative to tobacco, and the methods and methods of using these ingredients (see each of these references). Is incorporated herein by reference.)

  The sensory properties of smokeless tobacco can also be enhanced by incorporating certain flavoring materials. Exemplary flavoring agents or flavoring agents that can be used are ingredients that act to modify the bitterness, sweetness, sourness or saltiness of smokeless tobacco products, to enhance the perceived dryness or wetness of the formulation. An ingredient that acts, or an ingredient that acts to enhance the degree of tobacco taste exhibited by the formulation, or a suitable combination of these ingredients. Flavoring types include salts (eg sodium chloride, potassium chloride, sodium citrate, potassium citrate, sodium acetate, potassium acetate and the like), natural sweeteners (eg fructose, sucrose, glucose, Maltose, mannose, galactose, lactose and the like), artificial sweeteners (eg, sucralose, saccharin, aspartame, acesulfame K, neoterm and the like); and mixtures thereof. Flavoring agents may be natural or synthetic, and the characteristics of these flavors imparted by the flavoring agent include, but are not limited to, fresh, sweet, herbal, sugar confectionery, May be described as flowery, fruity, and spices. Specific types of fragrances include vanilla, coffee, chocolate / cocoa, cream, mint, spearmint, menthol, peppermint, wintergreen, eucalyptus, lavender, cardamom, nutmeg, cinnamon, clove, cascarilla, sandalwood, honey, jasmine, Examples include, but are not limited to, ginger, fennel, sage, licorice, lemon, orange, apple, peach, lime, cherry, strawberry and any combination thereof. See, eg, Leffingwill et al. , Tobacco Flavoring for Smoke Products, R .; J. et al. Reynolds Tobacco Company (1972); S. Patent Appl. Pub. No. 2002/0162562; Williams 2002/0162563; Atchley et al. 2003/0070687; Williams 2004/0020503; Breslin et al. 2005/0178398; Strickland et al. 2006/0191548; Holton, Jr. Et al., 2007/0062549; Holton, Jr. 2007/0186941; Strickland et al. 2007/0186942; Dube et al. 2008/0029110; Robinson et al. 2008/0029116; Mua et al. 2008/0029117; Robinson et al. 2008/0173317; and Neilsen et al. (Each of these references is hereby incorporated by reference). The amount of flavoring agent used in the tobacco product can vary, but typically is about 10 dry weight percent or less, and certain embodiments are at least about 0.5 dry weight percent, such as about 1 To about 10 dry weight percent total flavor content. In many cases, combinations of flavors can be used (eg, from about 0.1 to about 2 dry weight percent artificial sweetener and from about 0.5 to about 0.8 dry weight percent based on the total dry weight of the tobacco product. Sodium chloride).

  Exemplary filler materials include plant fiber materials such as sugar beet fiber materials (eg, FIBREX® trademark filler available from International Fiber Corporation), oats or other grain grains (processed or expanded grains). ), Bran fibers, starch, or other modified or natural cellulosic materials such as microcrystalline cellulose. Additional examples include corn starch, maltodextrin, dextrose, calcium carbonate, calcium phosphate, lactose, mannitol, xylitol and sorbitol. An example of a commercially available maltodextrin that can be used is Maltrin 10 DE available from Corn Products International. The amount of filler that can be used in the tobacco composition or formulation can vary, but typically can be about 60 dry weight percent or less, and certain embodiments have at least about 10 dry weight percent, such as Characterized by a filler content of about 20 to about 50 dry weight percent. Combinations of fillers may be used (eg, from about 2 to about 8 dry weight percent calcium carbonate, from about 10 to about 20 dry weight percent rice flour, and from about 10 to about 20 based on the total dry weight of the tobacco product. A mixture of dry weight percent maltodextrin).

  Preferred pH adjusting or buffering agents provide a pH range of about 6 to about 10 and / or buffer within the pH range of about 6 to about 10, and exemplary pH adjusting or buffering agents include metallic water Oxides, metal carbonates, metal bicarbonates and mixtures thereof. Specific exemplary materials include sodium hydroxide, potassium hydroxide, potassium carbonate, sodium carbonate and sodium bicarbonate. The amount of pH adjuster or buffer used in the tobacco formulation can vary, but is typically at least about 0.05 dry weight percent but about 5 dry weight based on the total dry weight of the tobacco product. Less than a percent. An exemplary amount of pH adjusting or buffering agent is about 1 to about 5 dry weight percent, based on the total weight of the tobacco product.

  Exemplary colorants include various dyes and pigments. For example, suitable colorants may include caramel colorants, titanium dioxide, beta carotene, black currants, redwood, grape skin, canthaxanthin, carrot powder or extract, or the like. The amount of colorant used in the tobacco formulation can vary, but is typically at least about 0.1 dry weight percent but not more than about 5 dry weight percent, based on the total dry weight of the tobacco product. . An exemplary amount of colorant is from about 0.5 to about 3 dry weight percent, based on the total weight of the tobacco product.

  Other materials such as preservatives (eg sodium or potassium sorbate, sodium or potassium benzoate, sodium or potassium propionate, sodium or potassium sulfite, sodium or potassium diacetate, parabens and methanol), disintegration aids (eg Microcrystalline cellulose, croscarmellose sodium, crospovidone, sodium starch glycolate, pregelatinized corn starch and the like) or anti-sticking agents (eg, Confecto ™ No-Stick marketed by International Foodcraft Corporation) 'N' ™ exemplary commercial product) can also be used. Typically, each such material is individually about 10 dry weight percent or less, and usually at least about 0.1 dry weight percent, such as about 0.5 to about 10 weight percent, based on the total dry weight of the tobacco product. Use in quantity.

  The tobacco product incorporates a binder system that incorporates at least one type of binder that exhibits thermoplastic properties, thermoplastic properties, or thermoplastic behavior (eg, the binder comprises: At least one thermoplastic polymer material). Accordingly, a thermoplastic binder system may incorporate a material or material to produce a binder that exhibits thermoplastic properties (eg, the binder, in combination with a plasticizer, at least one thermoplastic polymer). May consist of material and / or at least one thermoplastic binder). The amount of thermoplastic binder system used in a typical processed tobacco product is typically at least about 5 percent and often at least about 10 percent of the final molded product on a dry weight basis. The amount of thermoplastic binder-based material used in a typical processed tobacco product, on a dry weight basis, is generally less than about 40 percent, often less than about 35 percent, and often about 30 percent of the final molded product. Less than percent, and sometimes less than about 25 percent.

  There are various materials for thermoplastic binders. The term “thermoplastic” as used herein is a property of a material (for example, a polymer material), and the material softens or melts by heating to become a liquid, and the softened or melted liquid When it becomes cooled, it indicates the property of hardening or forming a gel. For example, a polymeric material that includes thermoplastic properties, thermoplastic properties or thermoplastic behavior softens or melts when exposed to heat and then returns to its original physical state type when cooled (eg, to ambient temperature). . Thus, contacting the thermoplastic binder with tobacco material and various other materials, mixing to cause physical contact between the binder and these materials, heating to polymer material of the thermoplastic binder system Softening or liquefying, and then cooling to cure the softened thermoplastic polymer material (and thus a tobacco product comprised of said material having a desirable physical binding property). As a result). Desirable thermoplastic polymeric materials for the present invention generally soften or melt at temperatures above about 50 ° C, often above about 60 ° C, and often above about 70 ° C (and thus thermoplastic properties). Present.)

  Examples of representative suitable thermoplastic polymer materials include hydroxypropyl cellulose, polyethylene oxide, certain cellulose ethers (eg, ethyl cellulose and hydroxypropyl methyl cellulose), polyvinyl alcohol and polyvinyl acetate. Examples of commercially available hydroxypropylcellulose include KLUCEL® EF, ELF and LF hydroxypropylcellulose (HPC) sold by Hercules Incorporated, Aqualon Division. An example of a commercially available polyethylene oxide is Polyox N10 sold by The Dow Chemical Company. Examples of commercially available ethyl cellulose include Ronas Chemicals Ind. Can be obtained from An example of a commercially available hydroxypropyl methylcellulose that can be used is Methocel ™ E50 sold by Hercules Incorporated, Aqualon Division. Examples of commercially available polyvinyl alcohol include E.I. I. Elvanol sold by DuPont de Nemours. Examples of commercially available polyvinyl acetate include E.I. I. Elvacet sold by DuPont de Nemours. See, for example, Fuizz's U.S. Pat. S. Patent Appl. Pub. No. See also thermoplastic polymers of the type shown in 2009/0095313, for example polymethyl acrylate. Typical thermoplastic polymeric materials exhibit thermoplastic properties at temperatures below about 140 ° C and more preferably below about 120 ° C. Highly preferred thermoplastic polymeric materials exhibit thermoplastic properties at temperatures below about 100 ° C and most preferably below about 90 ° C.

  The amount of thermoplastic polymer material used in a typical processed tobacco product is typically at least about 5 percent and often at least about 10% of the final molded product on a dry weight basis. The amount of thermoplastic polymer material used in a typical processed tobacco product is generally less than about 30 percent, often less than about 25 percent, typically less than about 20 percent and much more of the final molded product on a dry weight basis. Is less than about 15 percent.

  The binder system may incorporate a compound that can be characterized as a plasticizer. For example, the thermoplastic binder described above can be combined with and processed with at least one plasticizer. In some tobacco products, the binder system may be used with a plasticizer blend. In some tobacco products, the plasticizer blend may be premixed separately from mixing with the binder system or other materials. Highly preferred plasticizers are organic non-polymeric materials, and exemplary representative plasticizers include glycerin, propylene glycol, polyethylene glycol, polypropylene glycol, and combinations thereof. Certain plasticizers can be obtained with various polyols, such as medium and high molecular weight polyol type compounds. Some exemplary representative polyols include maltitol, sorbitol, isomalt, erythritol, xylitol, mannitol, polyglycitol and combinations thereof. The amount of plasticizer used in the tobacco product can vary. When used, the amount of plasticizer used in a typical processed tobacco product, on a dry weight basis, is typically at least about 1 percent, often at least about 2 percent and often at least about 2 percent of the final molded product. About 3 percent. When used, the amount of plasticizer used in a typical processed tobacco product, on a dry weight basis, is typically about 15 percent or less, often about 10 percent or less, and often about about 15 percent of the final molded product. 5 percent or less.

  Typically, the choice and amount of plasticizer is such that it results in a decrease in the softening temperature of the thermoplastic binder. The plasticizer can act to promote hydration and thus promote liquefaction of the thermoplastic binder. That is, it is possible to facilitate the molding of tobacco products at a relatively low temperature. Thus, the binder system in the tobacco formulation can reduce the operating temperature at which the tobacco formulation is molded, thereby reducing and / or avoiding burning and / or carbonization of the tobacco material. be able to. In addition, plasticizers reduce the need for large amounts of moisture or other liquid carrier materials and, as a result, reduce the need to boil off the drying stage after molding of tobacco products. For example, for a tobacco formulation incorporating a thermoplastic binder, a liquid (eg, water) and a plasticizer, a formulation suitable for extrusion of a desired tobacco product at a temperature generally below the normal melting temperature of the thermoplastic binder. Can be provided.

  Highly preferred thermoplastic binders that can suitably be used in combination with at least one plasticizer can vary. Examples of typical thermoplastic binders of this type include polyvinylpolypyrrolidone, methylcellulose, xanthan, gum arabic, maltodextrin, pullulan, certain modified starches and high molecular weight propylene glycols (eg above about 4000). Propylene glycol having a molecular weight). Examples of commercially available polyvinylpolypyrrolidone that can be used include Plasdone® K-29 / 32 sold by FMC BioPolymer. Examples of commercially available methylcellulose that can be used include Hercules Inc. , Polymer Materials from Methocel Series sold by Aqualon Division. Examples of commercially available xanthan and gum arabic that can be used include those available from TIC Gums. Examples of commercially available maltodextrins that can be used include Grain Processing Corp. Maltrin 10 DE available from Examples of suitable commercially available modified starches include Elastigel ™ 1000J and INSTANT TEXTTAID®-A sold by the National Starch and Chemical Company. An example of a suitable high molecular weight propylene glycol that can be used is PEG 4000 sold by The Dow Chemical Company. Suitable pullulan materials are described in Borschke et al., U.S. Pat. S. Patent Appl. Pub. No. 2007/0137668. When used in conjunction with an effective amount of plasticizer, such types of thermoplastic binders generally exhibit thermoplastic properties at temperatures below about 140 ° C and more preferably below about 120 ° C. Highly preferred thermoplastic binders exhibit thermoplastic properties at temperatures below about 100 ° C. These types of thermoplastic binders, which can be suitably used in combination with the above-mentioned plasticizers, can be used with thermoplastic polymer materials and optionally in the absence of plasticizers.

  The amount of thermoplastic binder used in a typical processed tobacco product can typically be at least about 5 percent and often at least about 10 percent of the final molded product on a dry weight basis. The amount of thermoplastic binder used in a typical processed tobacco product, on a dry weight basis, is generally less than about 30 percent, often less than about 25 percent, typically less than about 20 percent and many of the final molded product In some cases, it may be less than about 15 percent.

  Thermoplastic polymeric materials, thermoplastic binders used in conjunction with plasticizers, and mixtures of these materials can be processed with the processing and operating conditions of the invention described herein. Such thermoplastic polymeric materials, thermoplastic binders used in conjunction with plasticizers, and mixtures of these materials typically exhibit thermoplastic properties at temperatures below about 140 ° C and more preferably below about 120 ° C. To do. Highly preferred thermoplastic polymeric materials, thermoplastic binders used in conjunction with plasticizers, and mixtures of these materials used in combination with plasticizers exhibit thermoplastic properties at temperatures below about 100 ° C.

  The thermoplastic binder system can be used in combination with other binders. Representative of such other types of binders are carboxymethylcellulose and certain other modified cellulosic materials, alginates such as sodium alginate, certain starch-based binders, pectin, carrageenan, zein and the like (But not limited to). These types of binders may exhibit substantially no thermoplastic behavior or thermoplastic properties under the conditions and methods of the present invention. One exemplary carboxymethylcellulose is commercially available as Ac-Di-Sol® sold by FMC BioPolymer. Examples of suitable alginate include Algin 400 sold by TIC Gums and Manucol type alginate sold by FMC BioPolymer. An example of a suitable starch-based binder is alpha rice starch. Examples of suitable pectin and carrageenan are available from TIC Gums and FMC BioPolymer. Examples of suitable zeins are available from Alfa Chemicals. The amount of other optional binders used is, on a dry weight basis, typically less than about 20 percent, and often less than about 15 percent, and often less than about 10 percent of the final molded product. When used, the amount of other optional binders used is, on a dry weight basis, typically at least about 1 percent, and often at least about 3 percent, and often at least about 5 percent of the final molded product. Percent. In certain systems, these optional binders may require additional moisture when used in tobacco products.

  In some tobacco products, a plasticizer blend can be used in combination with a binder system. The plasticizer blend may include various polyols such as maltitol, sorbitol, isomalt, erythritol, xylitol, mannitol and polyglycitol; glycerin; propylene glycol; polyethylene glycol; polypropylene glycol; Some plasticizer blends may use syrup or liquid form polyols such as maltitol syrup or sorbitol liquid. The polyol in the syrup or liquid form may include at least 20 percent solids, at least 35 percent solids, at least 50 percent solids, at least 60 percent solids, at least 70 percent solids, or at least 75 percent solids. . The amount of plasticizer blend used is, on a dry weight basis, typically less than about 50 percent of the final molded product, often less than about 35 percent and often less than about 30 percent, and in other cases about Less than 25 percent. When used, the amount of plasticizer blend used in the tobacco product, on a dry weight basis, is typically at least about 5 percent, often at least about 15 percent and often at least about 20 percent of the final molded product. It is.

  For some tobacco products, the plasticizer blend can be prepared separately and then added to the premixed tobacco mixture and binder system. The plasticizer blend can be prepared by mixing the granule component and water. The plasticizer blend may be heated for a period of time and stirred until the plasticizer blend exhibits a clear, viscous liquid character. For some tobacco products, plasticizer blends can be prepared without mixing the granule ingredients with water. By mixing and heating the plasticizer blend separately from the tobacco mixture and binder system, the plasticizer blend can be heated to a higher temperature without concern about carbonization and / or burning of the tobacco mixture or other components. . When subjected to higher temperatures, the plasticizer blend may exhibit plastic type or viscoelastic properties. The viscosity at about 25 ° C. of such plasticizer blends is typically less than 25,000 centipoise (cp) and often less than 15,000 cp. When used in tobacco products, the viscosity of such plasticizer blends at about 25 ° C. is typically at least 100 cp and often at least 1500 cp. A tobacco product incorporating a plasticizer blend having such plastic-like or viscoelastic properties can provide a chewable tobacco product that does not collapse or fall apart in the user's mouth by mild to moderate chewing. Such chewable tobacco products can change shape in the mouth without being broken into small particles when chewed moderately to moderately.

  The manner in which the various components of the tobacco formulation can be combined can vary. The various components of the formulation can be brought into contact with, combined with, or mixed with each other in a conical blender, mixing drum, ribbon blender or the like. Thus, the entire mixture of various ingredients with granulated tobacco ingredients and other materials can actually be relatively homogeneous. For example, Solomon et al. S. Pat. No. 4, 148, 325; Korte et al. S. Pat. No. 6, 510, 855; and Williams et al. S. Pat. No. See a methodology of the type shown in US Pat. No. 6,834,654 (each of these references is hereby incorporated by reference). Any mixing technique or apparatus known in the art can be used to blend the components of the tobacco formulation together. The ingredients described herein, which may be in liquid or dry solid form, may be mixed with tobacco in a pre-treatment stage prior to mixing with any remaining ingredients of the composition, or simply all other It may be mixed with tobacco along with a liquid or dry material. A mixing method in which the materials of the tobacco composition are brought into close contact may be used. Mixing devices characterized by impellers or other structures capable of agitation are generally used. Exemplary mixing devices include casting drums, conditioning cylinders or drums, liquid spray devices, ribbon blenders, Littleford Day, Inc. And mixers available as FKM130, FKM600, FKM1200, FKM2000 and FKM3000, Plow Share type mixer cylinders, and the like.

  The components of the tobacco formulation can also be obtained by liquid material or material. The liquid material can be obtained in various ways and can be obtained from various sources. Tobacco formulations may be moist, and moisture is provided by the aqueous liquid supplied as the aqueous liquid itself, as wet tobacco or as a carrier liquid for the tobacco formulation material. Other liquid materials such as organic solvents (eg, ethanol) may be carrier fluids for certain materials of tobacco formulations. Thermoplastic binder-based plasticizers also generally have a liquid form.

  Tobacco formulations can have a relatively low to moderate water content when processed. The moisture content of the tobacco formulation during the processing stage is typically greater than about 5 percent, often greater than about 10 percent, and often about 15 percent, based on the total weight of the tobacco formulation and water. Can exceed. The moisture content of the tobacco formulation during the processing stage can typically be less than about 35 percent, often less than about 30 percent, and often about 25 percent, based on the total weight of the tobacco formulation and water. Less than a percent.

  Techniques for shaping tobacco products can vary, and various methods for shaping processed tobacco or for producing processed tobacco products will be readily apparent to those skilled in the tobacco product manufacturing industry. For example, a properly heated tobacco formulation that incorporates a thermoplastic binder system and has injectable, moldable or generally liquid properties can be cast into a sheet-like form and cooled well A highly binding sheet-like tobacco product can be produced. As another example, a suitably heated tobacco formulation incorporating a thermoplastic binder system can be molded into the desired shape and cooled. As yet another but preferred example, a tobacco formulation incorporating a thermoplastic binder system can be extruded from a heated extruder and cooled. As another example, a tobacco formulation incorporating a binder system and a premixed plasticizer blend can be extruded from a heated extruder and cooled.

  Tobacco products can be produced using hot melt extrusion techniques. That is, the processed tobacco formulation can be subjected to sufficient heat during the molding of the tobacco product, eliminating the need for any additional heat treatment steps. For example, the rapid evaporation of moisture from the processed tobacco formulation during the hot melt extrusion process can eliminate any need for further heating, drying or the like.

  A wide variety of extrusion techniques can be used to produce processed tobacco formulations such as multilayer tobacco pellets. For example, multilayer tobacco pellets can be produced using coextrusion techniques (eg, using a twin screw extruder). In such situations, the continuous wet or dry component or component mixture can be placed in a separate extrusion hopper. Steam, gas (eg, ammonia, air, carbon dioxide and the like), plasticizer (eg, glycerin or propylene glycol) and plasticizer blend as each dry mix is propelled, plasticized and heated. Can be poured into the extruder barrel and cooled. Thus, the various ingredients are processed so that they are very well mixed and thus in full contact with each other. For example, component contact is such that the individual components can be fully embedded in an extruded substrate or extrudate. See, for example, Toft et al., U.S. Pat. S. Pat. No. See 4,821,749. Multilayer materials can have the general form of a film, and alternatively, multi-layer, generally spherical materials can have various layers from the inside to the outside.

  Some shapes of smokeless tobacco products, such as rods or cubes, can be obtained by first extruding material through a mold having a desired cross-section (eg, circular or square), and then bringing the extruded material to a desired length. In some cases, it can be formed by cutting. For example, the shape of a smokeless tobacco product can be formed using an extrusion apparatus including a single or multi-screw extruder. Some extruders can include twin screw extruders, including co-rotating twin screw extruders. Various screw shapes can be used. For example, a screw having a combination of elements for feeding, mixing, pumping, shearing, and the like can be selected as desired for optimal results. Screws having sections or elements that have intermittent or non-composite blades or that are “counter bladed” or “reversible” and that provide a relatively large discharge rate can also be used. Typical screw elements and screws with combinations of such elements are available from extruder manufacturers. The extruder can be equipped with a barrel to heat the material introduced into the extruder. The extruder barrel can include multiple barrel zones. Extrusion setup conditions include, for example, dry blend material feed rate, wet blend material feed rate, screw RPM settings, temperature conditions, opening mold dimensions and barrel zone entry point for certain materials, and additional parameters. There can be various variations.

  Techniques and equipment for extruding tobacco material are described in U.S. Pat. S. Pat. No. 3,098,492; Tamol et al. 4,874,000; Graves et al. 4,880,018; Keritsis et al. 4,989,620; Luke et al. 5,072,744; White et al. 5,829,453 And White et al., 6,182,670, each of these references being incorporated herein by reference. Exemplary extruders suitable for use include industrial pasta extruders such as Model TP 200/300 available from Emiliomiti, LLC, Italy.

  In some methods that can be used to produce tobacco products, a portion of the material can be mixed and fed to an extruder. Additional material can be introduced at a different point or barrel zone of the extruder compared to other materials. For example, a premixed subgroup of materials can be fed into the first barrel zone of the extruder and contacted with a dry mix of other materials. One hopper or multiple hoppers can be used to assist in the loading of various materials into the extruder.

  The processed sheet-like material can be prepared by placing the tobacco composition on a moving belt, passing the moving belt through a nip made by opposing rolls, and then cutting the sheet to the desired length. Alternatively, the tobacco product can be overcoated with powder or liquid paint. In addition, if desired, the surface of the tobacco product can be embossed or printed.

  The pH of the tobacco product can vary. Typically, the pH of the formulation is at least about 6.5 and preferably at least about 7.5. Typically, the pH of the tobacco product will not exceed about 10, and in many cases will not exceed about 9.5. A typical tobacco product exhibits a pH of about 6.8 to about 8.2. An exemplary technique for determining the pH of a tobacco product is to disperse 5 g of this product in 100 mL of deionized water and measure the pH of the resulting suspension / solution (eg, with a pH meter). With that.

  The relative amount of tobacco combined with the additional components and binder system components can vary. The amount of tobacco material in the tobacco product is typically at least about 10 percent, generally at least about 25 percent, and often at least about 30 percent on a dry weight basis, based on the total dry weight of the processed formulation or final product. And often about 35 percent. In certain instances, the amount of other components and binder system components in the tobacco formulation may not exceed about 40 percent on a dry weight basis. A typical range of tobacco material in the formulation is from about 10 to about 60 weight percent, more often from about 20 to about 40 weight percent on a dry basis.

  The moisture content of a tobacco product before it is used by consumers can vary. Typically, the moisture content of tobacco products, such as tobacco blends in snus-type pouches, prior to being inserted into the user's mouth is less than about 55 weight percent and generally less than about 50 weight percent , And often less than about 45 weight percent. Certain types of tobacco products have a moisture content of less than about 15 percent by weight, often less than about 10 percent by weight and often less than about 5 percent by weight before use. The tobacco product can include a moisture content in the range of about 5 weight percent to about 15 weight percent prior to use. For certain tobacco products, such as those incorporating a Sunus type tobacco composition, the moisture content can exceed 20 weight percent, and often can exceed 30 weight percent. For example, a typical Sunus type product may have a tobacco composition that exhibits a moisture content of about 25 weight percent to about 50 weight percent, preferably about 30 weight percent to about 40 weight percent. For still other tobacco products, such as those in stick form, the tobacco product may contain a moisture content of about 5 weight percent to about 15 weight percent.

  Exemplary shapes for molded tobacco products include pills, tablets, spheres, sheets, films, coins, cubes, beads, oval, obloids, beans, cylinders, sticks and rods. Tobacco products of the present invention are smokeless tobacco compositions, such as loose wet snuff tobacco, dry dry snuff tobacco, chewing tobacco, pelleted tobacco pieces, compressed tobacco pieces, molded tobacco pieces, extruded or molded tobacco strips, pieces , Rods or sticks, finely pulverized powder, finely divided or finely divided agglomerates of powder pieces and ingredients, flake-like pieces, pieces of tobacco-containing gum, rolls of tape-like film, easily soluble in water or dispersed in water Possible films or strips (see, eg, Chan et al. US Patent Appl. Pub. No. 2006/0198873 and Fuisz US Pat. Appl. Pub. No. 2009/0095313), extruded or Molded stick or b Lids, extruded or molded tubes, layered or laminated materials (eg, multi-layer compositions having one type of tobacco formulation surrounded by different types of tobacco formulations), or outer shells (eg, transparent in nature) Certain colorless, translucent or highly colored, soft or hard shells) and tobacco or tobacco flavors (eg, Newtonian or thixotropic fluids that incorporate some form of tobacco) It can be used as a capsule-like material having an internal region. As an example, an extruded sheet or piece of film can be wrapped around a shaped tobacco-containing piece. As yet another example, an extruded piece can be subdivided into small pieces and incorporated with other tobacco materials in a snus-type pouch. A preferred form of tobacco product is a product having the form of an extruded piece or pieces of tobacco material and other materials held together using a binder system. Such extruded pieces can be processed or further subdivided into shaped pieces. For example, the extruded tobacco composition is physically processed in a roll press or otherwise, and then rolled into a roll for storage and later use, or cut into a desired shape for packaging and use Can do.

  Tobacco products that incorporate a thermoplastic binder system offer several advantages. In one respect, the binder system allows for efficient and effective extrusion of tobacco products (eg, tobacco products can be produced at a desired extrusion rate). In another respect, the tobacco formulation can be extruded at relatively low temperatures; thus, using a reduced amount of energy and under conditions that reduce the chances of tobacco material being burned or carbonized during processing. Tobacco formulations can be processed. In yet another aspect, a tobacco product having a reduced amount of binder can be provided, thus increasing the relative amount of tobacco and flavoring agent in the tobacco product, resulting in these The sensory characteristics of the product can be enhanced.

  Incorporation of binder systems into tobacco products by the methods described herein improves user satisfaction when using tobacco products as compared to tobacco products that rely on relatively high concentrations of thermoplastic polymers. be able to. In the case of tobacco formulations containing a high concentration of thermoplastic polymer, some users may experience a “sticky residue” in the mouth when using the tobacco product.

  Tobacco products incorporating premixed plasticizer blends can result in products that can be chewed moderately to moderately and do not fall apart in the user's mouth. Such tobacco products can change shape in the user's mouth without being broken into small particles when chewed moderately to moderately. By premixing the plasticizer blend, the material of the plasticizer blend can be heated to a temperature at which the plasticizer blend exhibits plastic type or viscoelastic properties. In many cases, such temperatures are higher than desirable for subjecting tobacco components during processing or manufacture. For example, the premixed plasticizer blend can be subjected to a temperature of about 100 ° C. to melt the plasticizer blend. This premixed and premelted plasticizer blend can then be added to the tobacco component and processed at temperatures below 100 ° C., for example from about 70 ° C. to about 85 ° C., resulting in carbonization of the tobacco and / or Or the risk of burning can be reduced and / or avoided.

  The invention can be more fully illustrated by the following examples. The examples are presented to illustrate some embodiments of the invention and should not be construed as limitations on the invention. All weight percentages are expressed on a dry weight basis (meaning excluding moisture) unless otherwise indicated.

[ Example 1 ]
Tobacco formulations for use as control formulation stick type smokeless tobacco products are provided as shown in Table 1. Smokeless tobacco products comprising the tobacco formulations of Table 1 can be used as a control formulation, as compared to further examples of the invention shown below or described below.

  The tobacco powder used in Example 1 is a blend of finely cured (-100 / + 270) Tyler mesh) full cured tobacco leaf and air cured tobacco stem. Add all dry ingredients (in powder form) and glycine and propylene glycol together to a Model 300D Littleford horizontal plow dough mixer (Littleford Day, Florence, Kent.) And mix well at about 150 rpm for about 15-20 minutes To do. The mixed dry blend is then switched to the hopper of a model ZSK26 Coperion extruder (Werner and Pfeiderer, Ramsey, NJ). The extruder barrel has an LD (length to diameter) ratio of 30: 1, an inner diameter of 26 inches, and consists of hot mold parts in addition to eight heating zones or compartments.

  The extruder is set at a screw speed of about 45 rpm and the barrel section and mold are operated at a temperature of about 100 ° C. For the dry blend, it is fed from the hopper to the extruder at a rate of about 10.5 lb / hr. The blend is extruded through a 3.0 mm diameter open mold into a 3 mm diameter cylindrical rod. The residence time of the blend in the extruder is approximately 55 seconds. These rods are cut into sticks approximately 61 centimeters in length and cured by drying with ambient air for approximately 10 to 20 minutes, after which the sticks are further cut into 3.5 mm pieces.

Binder-based formulations Tables AM provide various embodiments of binder systems that can be incorporated into tobacco formulations for use in tobacco products representative of the present invention. Binder systems prepared according to the recipes shown in Tables AM can be used in the tobacco formulations found in the examples described below.

  Prepare each batch of binder system by mixing the ingredients in a commercially available Kitchen Aid mixer for about 3 to 5 minutes.

[ Example 2-11 ]
Tobacco formulations for use as stick-type smokeless tobacco products as shown in Table 2-5 are provided as follows.

  A tobacco powder of the type shown in Example 1 is prepared. With the exception of glycine, all dry ingredients in powder form are added to the Model 300D Littleford horizontal plow dough mixer with the batch formulation and mixed well at about 150 rpm for about 15 to 20 minutes. Each batch formulation is prepared by mixing propylene glycol and / or water and binder in a 6 L Kitchen Aid mixer for about 5 minutes, and then mixing with other dry ingredients in a Littleford mixer. Each mixed formulation is then switched to the hopper of the ZSK26 Coperion extruder. Extrusion setup and operating parameters are essentially the same as Example 1, except that the barrel heating zone is operated at about 65 ° C. to 100 ° C. and the screw speed is set to 60 rpm. Separately, a wet blend is prepared by mixing glycine and water (10 percent total material loading equivalent) for about 5 minutes in a beaker using a stir bar.

  The mixed wet blend formulation is fed to the first barrel zone of the extruder. Feed to the extruder at a rate of 13.5 lb / hr for dry blends and 1.5 lb / hr for wet blend blends. The formulation is extruded through a 3.0 mm diameter open mold into a 3 mm diameter rod. These rods are cut into sticks approximately 61 centimeters in length and cured by drying with ambient air for approximately 10 to 20 minutes, after which the rods are further cut into sticks having a length of 3.5 mm.

  The tobacco product prepared as shown in Example 2-11 was prepared under extrusion conditions at a lower operating temperature than that of Example 1, thus reducing the possibility of carbonization or burning of the tobacco material and / or Or it requires lower energy to avoid and maintain at higher temperatures. In addition, the tobacco product prepared as shown in Example 2-11 has a shorter residence time in the extruder as well as a higher product throughput compared to Example 1.

[ Example 12-22 ]
A tobacco formulation for use as a sheet-type smokeless tobacco product as shown in Table 6-10 is provided as follows.

  Prepare tobacco powder essentially as shown in Example 1. Each of Examples 12-22 includes a perfume emulsion component having a formulation as shown in Table N. For Examples 12-15, all ingredients, including perfume emulsion, are added together to the Model 300D Series Littleford Plow Dough Mixer and mixed at about 150 rpm for about 15 to 20 minutes, after which the Coperion extruder hopper Switch to. For Examples 16-22, all ingredients including the perfume emulsion (see Table N) and the batch formulation are mixed in a Littleford mixer as described for Examples 12-15.

  For Examples 12-13, the extruder is set to a screw speed of 45 rpm and the barrel section and mold are operated at a temperature of about 100 ° C. A sheet mold having an opening of 75 mm × 0.85 mm is used. The dry blend is fed to the extruder at a rate of 7.5 lb / hr. Examples 12-13 do not use a wet blend formulation. The dry formulation is extruded into a continuous sheet that is about 0.85 mm thick. Sheets are extruded onto a conveyor belt and transported through a 30 ft long cooling tunnel (ABCO Automation, Inc., Greenborough, NC). The thickness of this sheet is further reduced by passing 3 sets of pin rolls, resulting in a flat sheet having a thickness of less than 0.4 mm. These sheets are cut into small strip pieces (about 2 cm x 2 cm pieces) of various shapes.

  For Examples 14-15, the setup before and after extrusion is similar to that shown for Examples 12-13, except that the extruder screw speed is set to 50 rpm and the wet blend formulation is used. Feed rates are 10.5 lb / hr for dry blend formulations and 1.5 lb / hr for wet blend formulations.

  For Examples 16-22, the pre-extrusion and post-extrusion setups are the same as in Examples 16-22 except that the extruder barrel temperature is operated from 75 ° C to 100 ° C, the screw speed is set to 60 rpm, and the wet blend is used. Similar to that shown for 12-13. The feed rate is 13.5 lb / hr for the dry blend formulation and 1.5 lb / hr for the wet blend formulation.

  Tobacco formulations or tobacco products prepared as shown in Examples 12-22 can have a lower operating temperature than that of conventional molding methods of tobacco products, thus allowing the carbonization or burning of tobacco materials. Lower energy is required to reduce and / or avoid performance and maintain at higher temperatures. In addition, tobacco formulations and tobacco products prepared as shown in Examples 12-22 can have a relatively short residence time in the extruder and a high throughput of processed tobacco products.

[ Example 23-30 ]
Tobacco formulations for use as fusible cylinder, rod, stick, bean, egg, sphere, or strip type smokeless tobacco products are provided as shown in Table 11. A smokeless product comprising the tobacco formulation of Table 11 can be used as a control formulation compared to the further examples described in Tables 12-18 shown below and described below.

  The tobacco powder used in Example 23 shown in Table 11 was refined (−100 / + 200) Tyler mesh) full cured tobacco leaf, full cured tobacco starch fraction and air cured tobacco. A blend with stems. All dry ingredients (in powder form) and liquid mint flavor are added together to a Model 300D Littleford horizontal plow dough mixer (Littleford Day, Florence, Kent.) And mixed well at about 150 rpm for about 10 minutes.

  Plasticizer blends shown in Table 11 are also used in tobacco formulations. This blend is fed into the first barrel zone of the extruder and added to the premixed tobacco and binder blend. The plasticizer blend is prepared separately by mixing the granular ingredients and water (about 7.5 percent to about 13 percent total stock loading equivalent) in a stainless steel container. The container is heated to about 100 ° C. and held at about 80 ° C. to about 100 ° C. for 10 minutes or until the contents are a clear, viscous liquid (12,000 cP or less). The contents are constantly stirred during this heating period. The plasticizer blend is then transferred to a K-Tron tank with a thermal control jacket connected inline with a model ZSK26 Coperion extruder (Werner and Pfeiderer, Ramsey, NJ).

  The extrusion barrel has an LD (length to diameter) ratio of 30: 1, an inner diameter of 26 inches, and consists of hot mold parts in addition to eight heating zones or compartments. The extruder is set to a screw speed of about 60 to about 70 rpm, while the eight barrel zones and mold are operated at about 70 to about 85 ° C. Feed the extruder from the hopper at a rate of about 13.5 lb / hr for the dry blend and from the K-Tron storage tank to the extruder at a rate of 7.6 lb / hr for the plasticizer solution. The formulation is extruded through a 7.5 mm diameter open mold into a 7.5 to 8.0 mm cylindrical rod or through a 2.5 mm sheet mold into a 2.5 to 3 mm thick sheet. The residence time of the blend in the extruder is approximately 55 to 60 seconds.

  These rods or sheets are extruded onto a conveyor belt and transported through a 30 ft long cooling tunnel (available through ABCO Automation, Inc., Greenborough, NC). The rod and sheet are cut into pieces approximately 65 centimeters long and transferred onto a perforated drying tray (75 cm × 75 cm). The tray is transferred to a forced air oven and dried at about 127 ° C. for 5 minutes and then cooled to ambient temperature for surface hardening (15-20 minutes). These sticks are further cut into 14.5 mm rod-shaped pieces or roll pressed and 5.5 to 6.0 mm (height) x 8.5 to 9.0 mm (width) x 14.5 mm (length) Cut into pillow-shaped pieces. These sheets (single, double or triple layered) are fed through an automatic drop roller press (available through General Electric Co, Statol Jr. (TM), USA) to form and cut the sheet Into strips, beans, spheres or oval pieces.

  Tobacco formulations for use as fusible cylinder, rod, stick, bean, egg-shaped, spherical or strip type smokeless tobacco products are provided as shown in Table 12. The tobacco formulation described in Table 24, Example 24, except that the extruder feed rate is set to about 15.0 lb / hr for the dry blend and the plasticizer blend feed rate is set to about 8.3 lb / hr. Processed as shown in Example 23.

  Tobacco formulations for use as fusible cylinder, rod, stick, bean, egg, sphere, or strip type smokeless tobacco products are provided as shown in Table 13. The tobacco formulation described in Example 25 is the same as in the Example except that the extruder feed rate is set to about 15.0 lb / hr for the dry blend and the plasticizer blend feed rate is set to about 8.3 lb / hr. Process as shown in FIG. In addition, in Example 25, perfume is introduced into the formulation by a binder system as opposed to Example 23.

  Tobacco formulations for use as a fusible column, rod, stick, bean, egg, sphere, or strip type smokeless tobacco product are provided as shown in Table 14. The tobacco formulation described in Example 26 is processed as shown in Example 23 except that the plasticizer blend feed rate is set to 6.0 lb / hr. In addition, in Example 26, perfume is introduced into the formulation by a binder system as opposed to Example 23.

  Tobacco formulations for use as fusible cylinder, rod, stick, bean, egg, sphere, or strip type smokeless tobacco products are provided as shown in Table 15. The tobacco formulation described in Example 27 does not preheat the plasticizer solution before introducing the plasticizer blend into the extruder, sets the extruder feed rate to about 15.0 lb / hr for the dry formulation, and plastics. Process as shown in Example 23 except that the agent blend feed rate is set at about 7.25 lb / hr.

  Tobacco formulations for use as fusible cylinder, rod, stick, bean, egg, sphere, or strip type smokeless tobacco products are provided as shown in Table 16. The tobacco formulation described in Example 28 is prepared by melting the plasticizer blend by adding the granule components of the plasticizer blend without adding water; the extruder feed rate is about 11. Process as shown in Example 23, except setting 50 lb / hr; and setting the plasticizer blend feed rate to about 3.71 lb / hr.

  Tobacco formulations for use as fusible cylinder, rod, stick, bean, egg-shaped, spherical or strip-type smokeless tobacco products, as shown in Examples 29 and 30 (shown in Tables 17 and 18, respectively). provide. In Examples 29 and 30, high shear mixing for about 15 to 20 minutes using a commercially available mixer (Model 28bl62 Waring blender available from Waring Co., Turlington, Conn.) Causes the binder system to reach about the weight of the binder system. Hydrate with 8 to about 10 times the water. The plasticizer blends of Examples 29 and 30 prepared as shown in Example 23 are added to the high shear mixture and mixed well for about 10 to 15 minutes. The binder system and plasticizer blend mixture is then transferred to a mixer equipped with a mixing spindle, such as a commercially available Kitchen Aid or Hobart mixer. The tobacco composition is then transferred to the mixer and mixed well for about 5 to 10 minutes to form a semi-viscoelastic to solid viscoelastic mass or dough-like composition. The dough-like composition is flattened by a manual two-roll press to obtain a sheet having a thickness of 4 to 5 mm. The sheet is stored for about 12 to 18 hours at about 60 ° C. from ambient temperature and about 25 to about 40 percent relative humidity. After storage, the sheet is fed through a drop roller press, which forms and cuts the sheet into various sizes and shapes as described in Example 23.

  Tobacco formulations or tobacco products prepared as shown in Examples 23-30 can have a lower operating temperature of the extruder than that of conventional molding methods of tobacco products, so that In addition to reducing and / or avoiding the possibility of burning, chewable tobacco products can still be produced. By premixing the plasticizer blend, the plasticizer blend stock can be heated outside the extruder barrel zone to a temperature at which the plasticizer exhibits plastic-type or viscoelastic properties.

  Many variations and other embodiments of the invention will occur to those skilled in the art to which the invention pertains that benefit from the teachings presented in the foregoing description. Accordingly, it should be understood that the invention should not be limited to the specific embodiments disclosed, and that variations and other embodiments are construed as included within the scope of the appended claims. Although specific terms are used herein, these terms are used in a generic and descriptive sense only and not for purposes of limitation.

Claims (23)

  A tobacco product in a form suitable for insertion into a user's mouth, comprising tobacco and a thermoplastic binder system, wherein the amount of tobacco is from about 10 to about 60 weight percent of the dry weight of the tobacco product; The amount of the thermoplastic binder system is present in an amount less than about 30 weight percent of the dry weight of the tobacco product, and the amount of the thermoplastic binder system is less than about 20 weight percent of the dry weight of the tobacco product. At least one thermoplastic polymer material, at least one thermoplastic binder in an amount of from about 5 to about 20 weight percent of the dry weight of the tobacco product, and from about 3 to about 15 weight percent of the dry weight of the tobacco product. A tobacco product comprising an amount of at least one plasticizer.   The tobacco product of claim 1, wherein the thermoplastic polymer material exhibits thermoplastic behavior at a temperature of less than about 100 ° C.   The tobacco product of claim 1, wherein the thermoplastic binder comprises pullulan.   The tobacco product of claim 1, wherein the thermoplastic binder comprises pullulan and gum arabic.   The tobacco product of claim 1, wherein the thermoplastic binder comprises pullulan, gum arabic and xanthan.   The tobacco product of claim 1, wherein the plasticizer comprises at least one of glycerin, propylene glycol, polypropylene glycol, or polyethylene glycol.   The tobacco product of claim 1 further comprising a plasticizer blend.   8. The tobacco product of claim 7, wherein the plasticizer blend comprises at least one of sorbitol liquid, maltitol syrup or polyglycitol.   8. The tobacco product of claim 7, wherein the plasticizer blend comprises at least one of erythritol, isomalt, xylitol, or mannitol.   The tobacco product of claim 7, wherein the plasticizer blend comprises at least one of glycerin, propylene glycol, polypropylene glycol or polyethylene glycol. Plasticizer blend
At least one of sorbitol, maltitol syrup or polyglycitol;
8. The tobacco product of claim 7, comprising at least one of erythritol, isomalt, xylitol, or mannitol; and at least one of glycerin, propylene glycol, polypropylene glycol, or polyethylene glycol.   The tobacco product of claim 1, wherein the thermoplastic binder exhibits thermoplastic behavior at a temperature of less than about 100 ° C.   The tobacco product of claim 1, wherein the thermoplastic binder system exhibits thermoplastic behavior at a temperature of less than about 100 degrees Celsius.   The tobacco product of claim 1 further comprising a plasticizer blend. A method for producing a smokeless tobacco product, comprising:
Contacting the tobacco material with a thermoplastic binder system to obtain a mixture, comprising:
The tobacco material is present in an amount of about 10 to about 60 weight percent of the dry weight of the tobacco product , and the thermoplastic binder system is present in an amount of about 10 to 25 weight percent of the dry weight of the tobacco product. And wherein the thermoplastic binder system incorporates at least one thermoplastic polymer material in an amount less than about 15 weight percent of the dry weight of the tobacco product;
Subjecting the mixture to an elevated temperature;
Forming the mixture into a desired shape of the tobacco product; and cooling the tobacco product.   16. The method of claim 15, wherein the thermoplastic binder system incorporates at least one thermoplastic binder and at least one plasticizer.   The method of claim 15, wherein the mixture comprises less than about 30 weight percent thermoplastic binder system, based on the total dry weight of the tobacco product.   16. The method of claim 15, wherein forming the mixture involves subjecting the mixture to a temperature less than about 100 ° C.   16. The method of claim 15, wherein during molding, the mixture has a moisture content greater than about 5 weight percent, based on the total weight of tobacco product and moisture.   16. The method of claim 15, further comprising contacting the mixture with a plasticizer blend prior to subjecting the mixture to an elevated temperature.   The method of claim 16, wherein the plasticizer blend is heated prior to contacting the mixture with the plasticizer blend. A tobacco product in a form suitable for insertion into a user's mouth, comprising tobacco, a binder system and a plasticizer blend, wherein the binder system is in an amount of about 10 to about 25 weight percent of the dry weight of the tobacco product. The plasticizer blend is present in an amount of about 15 to about 30 weight percent of the dry weight of the tobacco product ;
The binder system comprises at least one thermoplastic polymer material in an amount less than about 15 weight percent of the dry weight of the tobacco product and at least one thermoplastic binder in an amount of from about 5 to 15 weight percent of the dry weight of the tobacco product; Including
The plasticizer blend, et Risuritoru, isomalt, at least one of xylitol or mannitol; including and propylene glycol, glycerin, at least one of polypropylene glycol or polyethylene glycol, tobacco products.   24. The tobacco product of claim 22, wherein the tobacco product is chewable.