US20160192698A1

US20160192698A1 - Apparatus for use in the formation of a tobacco rod

Info

Publication number: US20160192698A1
Application number: US14/988,104
Authority: US
Inventors: Dwight David Williams
Original assignee: Altria Client Services LLC
Current assignee: Altria Client Services LLC
Priority date: 2015-01-05
Filing date: 2016-01-05
Publication date: 2016-07-07

Abstract

An apparatus for the formation of machine-made tobacco rods for use in the production of cigars. The apparatus includes a lower conveyor belt and an upper compression belt for receiving and compressing the stream of tobacco, the lower conveyor belt and upper compression belt driven by a plurality of pulleys; a pair of squeeze bars for compressing the tobacco in a direction perpendicular to the pair of transfer and compression belts, the pair of squeeze bars coated with a poly-condensated silicone or a polymeric silazane finish; a tongue for receiving the compressed tobacco, the tongue coated with a poly-condensated silicone or a polymeric silazane finish; and a short folder for folding a wrapper material around the compressed tobacco so as to form a continuous rod of tobacco for use in the production of cigars, the short folder coated with a poly-condensated silicone or a polymeric silazane finish.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of the filing date of U.S. Provisional Application No. 62/099,890 filed Jan. 5, 2015, the contents of which are hereby incorporated by reference in their entirety.

FIELD

The present invention generally relates to the manufacture of smoking articles, more specifically, cigar manufacturing and, in particular, to a method and apparatus for the formation of machine-made tobacco rods for use in the production of cigars.

ENVIRONMENT

In the manufacture of machine-made cigars, it is essential that tobacco be utilized as efficiently as possible due to its relatively high cost. In modern cigar manufacturing, it is also desirable to closely control the quantity of tobacco contained in each cigar, so as to provide a cigar that is considered well filled and is well filled on a consistent basis.
The manufacture of machine-made cigars may present a further problem impacting tobacco utilization, which relates to the particular tobacco blend sought to be employed. Machine-made cigars produced from pipe-tobacco blends have achieved wide acceptance in the market place. However, pipe-tobacco blends may have a degree of tackiness imparted thereto by the flavorants and other additives employed to enhance smoking enjoyment. The tacky, tobacco borne materials tend to stick to and accumulate along, guides, plows, garniture folding surfaces and the like of tobacco rod forming machines and other tobacco handling apparatus. Machines for making tobacco rods from pipe-tobacco blends are often modified to increase the clearances between parts (such as between a belt and a guide adjacent the belt) to accommodate the tacky pipe-tobacco blends, increasing the likelihood that the tobacco will escape and be utilized less efficiently, with greater tobacco waste.
There is a need for an improved method and apparatus for the manufacture of tobacco products, including machine-made cigars from tacky tobaccos, which will provide satisfactory cigars and be efficient in the use of tobacco.

SUMMARY

In one aspect, provided is a method of decreasing tobacco waste during the formation of machine-made tobacco rods for use in the production of cigars from tobacco having a tacky material combined therewith, The method includes the steps of providing a plurality of components of a cigar rod-making machine, the plurality of components coated with a poly-condensated silicone or a polymeric silazane finish; and reducing at least one clearance gap between at least one of the plurality of components with an adjacent component of the cigar rod-making machine to reduce the amount of tobacco escaping through the gap.
In one form, the method further includes the step of operating the cigar rod-making machine to produce cigar rods from the tobacco having a tacky material combined therewith, wherein tobacco wasted in the production of cigar rods is decreased.
In another form, the tobacco wasted in the production of cigar rods is decreased by at least 25%.
In yet another form, the tobacco wasted in the production of cigar rods is decreased by at least 50%.
In still yet another form, the tobacco wasted in the production of cigar rods is decreased by at least 80%.
In one form, the plurality of components include components having surfaces that contact the tobacco.
In a further form, the plurality of components are selected from a pair of squeeze bars (or guides or plows or rails) for compressing the tobacco, one or more pulleys for advancing transfer and/or compression belts, a tongue for guiding the tobacco, a short folder, or any combination thereof.
In another aspect, provided is an apparatus for the formation of machine-made tobacco rods for use in the production of cigars from tobacco having a tacky material combined therewith. The apparatus includes a lower conveyor belt and an upper compression belt for receiving and compressing the stream of tobacco, the lower conveyor belt and upper compression belt driven by a plurality of pulleys; a pair of squeeze bars for compressing the tobacco in a direction perpendicular to the pair of transfer and compression belts, the pair of squeeze bars coated with a poly-condensated silicone or a polymeric silazane finish; a tongue for receiving the compressed tobacco, the tongue coated with a poly-condensated silicone or a polymeric silazane finish; and a short folder for folding a wrapper material around the compressed tobacco so as to form a continuous rod of tobacco for use in the production of cigars, the wrapper material provided from a source of wrapper material, the short folder coated with a poly-condensated silicone or a polymeric silazane finish.
In one form, each of the plurality of pulleys is coated with a poly-condensated silicone or a polymeric silazane finish.
In yet another form, the apparatus includes a second heater bar for further curing the glue and sealing the wrapper material to form the continuous rod of tobacco for use in the production of cigars.
In another aspect, provided is a method for the formation of machine-made tobacco rods for use in the production of cigars from tobacco having a tacky material combined therewith. The method includes providing a stream of tobacco in a substantially uniform format; receiving and compressing the stream of tobacco between a lower conveyor belt and an upper compression belt, the lower conveyor belt and upper compression belt driven and guided by a plurality of pulleys; compressing the tobacco in a direction perpendicular to the pair of transfer and compression belts between a pair of squeeze bars, the pair of squeeze bars coated with a poly-condensated silicone or a polymeric silazane finish; conveying the compressed tobacco downstream to a tongue, the tongue coated with a poly-condensated silicone or a polymeric silazane finish; providing a wrapper material from a source of wrapper material; and folding the wrapper material around the compressed tobacco so as to form a continuous rod of tobacco for use in the production of cigars.
In one form, the step of folding the wrapper material around the compressed tobacco so as to form a continuous rod of tobacco for use in the production of cigars utilizes a short folder coated with a poly-condensated silicone or a polymeric silazane finish.
In another form, each of the plurality of pulleys is coated with a poly-condensated silicone or a polymeric silazane finish.
In yet another aspect, provided is a method of decreasing the waste of a tacky shredded material in the machine formation of a formed body. The method comprises the steps of providing a plurality of forming machine components, the plurality of components coated with a poly-condensated silicone or a polymeric silazane finish and characterized by a resistance to collecting the tacky shredded material and having a degree of wear resistance; and reducing at least one clearance gap between at least one of the plurality of components with an adjacent component of the forming machine to reduce the possibility that the tacky shredded material escapes through the gap.
In still yet another aspect, provided is a method of forming a rod from a shredded material and a wrapper, the shredded material including a tacky constituent, the method comprising: establishing a moving column of the shredded material; compressing the column by moving the column along opposing converging guides coated with a poly-condensated silicone or a polymeric silazane finish; forming the rod by drawing the compressed column and the wrapper through a folding surface coated with a poly-condensated silicone or a polymeric silazane finish.
In one form, the step of establishing includes moving a lower endless belt adjacent a feeder while guiding the lower belt with a guide plate coated with a poly-condensated silicone or a polymeric silazane finish.
In another form, the step of compressing includes compressing the column with convergent, opposing endless belts.
In still another form, the method includes the step of abating accumulation of shredded material by providing a guide piece coated with a poly-condensated silicone or a polymeric silazane finish at a transition space between sets of convergent, opposing endless belts.
In a further aspect, provided is an apparatus capable of forming a rod from a shredded material and a wrapper, the shredded material including a tacky constituent. The apparatus includes a feeder that establishes a moving column of the shredded material; opposing converging guides that compress the column as the column moves along the opposing converging guides, the opposing converging guides coated with a poly-condensated silicone or a polymeric silazane finish; a folding surface that forms the rod as the compressed column and the wrapper are drawn through the folding surface, the folding surface coated with a poly-condensated silicone or a polymeric silazane finish.
In one form, the feeder includes moving a lower endless belt and a guide plate that guides the lower endless belt, the guide plate coated with a poly-condensated silicone or a polymeric silazane finish.
In another form, the opposing converging guides cooperate with convergent, opposing endless belts to compress the column.
In still another form, the apparatus further includes a transition guide at a transition space between sets of convergent, opposing endless belts, the transition guide abating accumulation of shredded material and coated with a poly-condensated silicone or a polymeric silazane finish.

BRIEF DESCRIPTION OF THE DRAWINGS

The forms disclosed herein are illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings and in which like reference numerals refer to similar elements and in which:

FIG. 1a schematically presents an apparatus for the formation of machine-made tobacco rods, in accordance herewith;

FIG. 1b is a side planar view of squeeze bar 60, as shown in FIG. 1 b;

FIG. 2 is a cross-sectional view taken through section 2-2 of FIG. 1 a;

FIG. 3 schematically presents a top view of the in-feed section of an apparatus for the formation of machine-made tobacco rods for use in the production of cigars, in accordance herewith;

FIG. 4 presents an exploded view of Section A of FIG. 1 a;

FIG. 5 is a cross-sectional view taken through Section 5-5 of FIG. 1 a;

FIG. 6 is a cross-sectional view taken through Section 6-6 of FIG. 1a ; and

FIGS. 7-10 present cross-sectional views of a tobacco rod as it progresses through the folding or rolling operation.

DETAILED DESCRIPTION

Various aspects will now be described with reference to specific forms selected for purposes of illustration. It will be appreciated that the spirit and scope of the apparatus, system and methods disclosed herein are not limited to the selected forms. Moreover, it is to be noted that the figures provided herein are not drawn to any particular proportion or scale, and that many variations can be made to the illustrated forms. Reference is now made to FIGS. 1-10, wherein like numerals are used to designate like elements throughout.
Each of the following terms written in singular grammatical form: “a,” “an,” and “the,” as used herein, may also refer to, and encompass, a plurality of the stated entity or object, unless otherwise specifically defined or stated herein, or, unless the context clearly dictates otherwise. For example, the phrases “a device,” “an assembly,” “a mechanism,” “a component,” and “an element,” as used herein, may also refer to, and encompass, a plurality of devices, a plurality of assemblies, a plurality of mechanisms, a plurality of components, and a plurality of elements, respectively.
Each of the following terms: “includes,” “including,” “has,” “having,” “comprises,” and “comprising,” and, their linguistic or grammatical variants, derivatives, and/or conjugates, as used herein, means “including, but not limited to.”
Throughout the illustrative description, the examples, and the appended claims, a numerical value of a parameter, feature, object, or dimension, may be stated or described in terms of a numerical range format. It is to be fully understood that the stated numerical range format is provided for illustrating implementation of the forms disclosed herein, and is not to be understood or construed as inflexibly limiting the scope of the forms disclosed herein.
Moreover, for stating or describing a numerical range, the phrase “in a range of between about a first numerical value and about a second numerical value,” is considered equivalent to, and means the same as, the phrase “in a range of from about a first numerical value to about a second numerical value,” and, thus, the two equivalently meaning phrases may be used interchangeably.
It is to be understood that the various forms disclosed herein are not limited in their application to the details of the order or sequence, and number, of steps or procedures, and sub-steps or sub-procedures, of operation or implementation of forms of the method or to the details of type, composition, construction, arrangement, order and number of the system, system sub-units, devices, assemblies, sub-assemblies, mechanisms, structures, components, elements, and configurations, and, peripheral equipment, utilities, accessories, and materials of forms of the system, set forth in the following illustrative description, accompanying drawings, and examples, unless otherwise specifically stated herein. The apparatus, systems and methods disclosed herein can be practiced or implemented according to various other alternative forms and in various other alternative ways.
It is also to be understood that all technical and scientific words, terms, and/or phrases, used herein throughout the present disclosure have either the identical or similar meaning as commonly understood by one of ordinary skill in the art, unless otherwise specifically defined or stated herein. Phraseology, terminology, and, notation, employed herein throughout the present disclosure are for the purpose of description and should not be regarded as limiting.
As can be the case in the manufacture of certain machine-made cigars, the tobacco may have a tacky material combined therewith prior to rod formation, such as by way of addition of flavorants and other additives. Examples of suitable types of tobaccos that may be used in the manufacture of machine-made cigars include, but are not limited to, flue-cured tobacco, Burley tobacco, Maryland tobacco, Oriental tobacco, rare tobacco, specialty tobacco, reconstituted tobacco, blends thereof and the like. Optionally, the tobacco may be pasteurized. In the alternative, the tobacco material may be fermented.
Suitable flavorants and aromas include, but are not limited to, any natural or synthetic flavor or aroma, such as tobacco, smoke, menthol, mint (such as peppermint and spearmint), chocolate, licorice, citrus and other fruit flavors, gamma octalactone, vanillin, ethyl vanillin, breath freshener flavors, spice flavors such as cinnamon, methyl salicylate, linalool, bergamot oil, geranium oil, lemon oil, and ginger oil. Other suitable flavors and aromas may include flavor compounds selected from the group consisting of an acid, an alcohol, an ester, an aldehyde, a ketone, a pyrazine, combinations or blends thereof and the like. Suitable flavor compounds may be selected, for example, from the group consisting of phenylacetic acid, solanone, megastigmatrienone, 2-heptanone, benzylalcohol, cis-3-hexenyl acetate, valeric acid, valeric aldehyde, ester, terpene, sesquiterpene, nootkatone, maltol, damascenone, pyrazine, lactone, anethole, iso-valeric acid, combinations thereof and the like.
Exemplary additional natural and artificial flavorants include, but are not limited to, peppermint, spearmint, wintergreen, menthol, cinnamon, chocolate, vanillin, licorice, clove, anise, sandalwood, geranium, rose oil, vanilla, lemon oil, cassia, fennel, ginger, ethylacetate, isoamylacetate, propylisobutyrate, isobutyl butyrate, ethylbutyrate, ethylvalerate, benzylformate, limonene, cymene, pinene, linalool, geraniol, citronellol, citral, orange oil, coriander oil, borneol, fruit extract, and the like. Particularly preferred additional flavor and aroma agents are essential oils and/or essences of coffee, tea, cacao, and mint.
Humectants can also be added to the tobacco material to help maintain the moisture levels. Examples of humectants that can be used with the tobacco include glycerol and propylene glycol. It is noted that the humectants can also be provided for a preservative effect, as the water activity of the product can be decreased with inclusion of a humectant, thus reducing opportunity for growth of micro-organisms. Additionally, humectants can be used to provide a higher moisture feel to a drier tobacco component.
In one form, the tobacco used in the manufacture of machine-made cigars employing the apparatus and methods disclosed herein is a pipe tobacco blend having a degree of tackiness imparted thereto.
Referring to FIG. 1, an apparatus 10 for the formation of machine-made tobacco rods is schematically presented. Advantageously, apparatus 10 is particularly useful in the production of cigars from tobacco having a tacky material combined therewith. One such application is the production of cigars from a form of pipe tobacco.
As shown, apparatus 10 includes a tobacco feed section 12, an in-feed section 14 and a finishing section 16. Tobacco feed section 12 may include at least one conveyer (not shown) for receiving the stream of tobacco from a source of tobacco. Tobacco feed section 12 may also include at least one electromagnetic vibrator (not shown) for providing the stream of tobacco in a substantially uniform format. Suitable electromagnetic vibrators 18 are available from Eriez Corporation of Erie, Pa. and possess the ability provide for the relatively high speed feeding of light, bulky materials.
In one form, in-feed section 12 may be constructed from existing equipment, such as an in-feed section of an AMF cigarette making machine. Finishing section 16 may also be constructed from existing equipment, such as a Molins Mk 8 or Mk 9 machine, available from Molins PLC of Milton Keynes, UK.
Referring still to FIG. 1, in one form, a vibratory waterfall feeder 20 is positioned downstream of the tobacco feed section 12 for receiving the stream of tobacco. Vibratory waterfall feeder 20 feeds tobacco to an in-feed section 14, establishing a column of tobacco along lower conveyor belt 24, which is driven and guided by a plurality of pulleys 26. The lower conveyor belt 24 is kept in tension by a biased tension pulley 28. The stream of tobacco may optionally proceed past a trimmer unit 22, to establish a uniform height along the column of tobacco established atop the lower conveyor belt 24 by the vibratory waterfall feeder 20.
Referring now to FIG. 2, a view of apparatus 10 taken through Section 2-2 is presented. As shown, lower conveyor belt 24 rides above a conveyor guide 70, the conveyor guide 70 being positioned within conveyer base plate 72. Tobacco T from vibratory waterfall feeder 20 is deposited upon lower conveyor belt 24. A first trough member 74 and a second trough member 76 guide the tobacco T onto the lower conveyor belt 24. First trough member 74 is affixed to a first angle bracket 78 and second trough member 76 is affixed to a second angle bracket 80. As shown, first angle bracket 78 and second angle bracket 80 may extend over a portion of lower conveyor belt 24 so as to maintain the position of lower conveyor belt 24 within conveyer base plate 72.
Referring again to FIG. 1, in one form, the in-feed section 14 includes an upper (compression) belt 50 positioned downstream of vibratory waterfall feeder 20, above and in opposing relation with at least a portion of lower conveyor belt 24 and is likewise disposed with at least a portion of transfer or garniture tube belt 42. Upper compression belt 50 and a portion of transfer or garniture tube belt 42 are configured to receive and compress the stream of tobacco. Compression belt 50 is driven and guided by a plurality of pulleys 52 and is kept in tension by a tension pulley 54.
Referring also to FIG. 3, squeeze bars 60 and 62 are provided in a mutually opposing, converging relation for compressing the tobacco in a transverse direction (side to side), while also compression belt 50 and lower conveyor belt 24 are in a mutually opposing, converging relation for compressing the tobacco from top to bottom of the tobacco column. At the furthest end of lower conveyor belt 24, the tobacco column is transferred from lower conveyor belt 24 onto a binder web 30, which is supplied from a source of binder web 32. Binder web 30 is mated with wrapper web 34, which is supplied from a source of wrapper web 36, and is supported and drawn by a transfer or garniture tube belt 42. In the embodiments, the binder web 30 and the wrapper web 34 comprise tobacco.
Referring now to FIG. 4, an exploded schematic view of Section A of FIG. 1 is presented. As shown, in one form, a transition piece 56 is employed to bridge the transition from lower conveyor belt 24 to transfer or garniture tube belt 42, creating a smoother path for a tobacco column to traverse. Additionally, the transition piece 56 serves to reduce the level of turbulence that might otherwise be imparted to a tobacco column traversing the transition from lower conveyor belt 24 to transfer or garniture tube belt 42. The transition piece 56 occupies space at the transition between belts 24 and 42, which space would otherwise allow tobacco to accumulate and intermittently release, with impact on product consistency.
Referring again to FIG. 1, the formation of the tobacco column will be described in more detail. As the tobacco stream enters the arrangement formed by the pair of squeeze bars 60 and 62, lower conveyor belt 24, and upper compression belt 50, the cross-sectional area of the arrangement is continuously reduced, forcing the tobacco to be compressed into an ever-smaller cross-section, until it reaches the desired cross-sectional dimension. Referring to FIG. 5, a cross-sectional view of Section 5-5 of FIG. 1 is presented. As may be seen a cross-sectional-area is formed by the arrangement formed by squeeze bars 60 and 62, lower conveyor belt 24, and upper compression belt 50. Moving along apparatus 10 to Section 6-6 of FIG. 1, reference is made to FIG. 6, wherein a reduced cross-sectional-area is depicted. As one of ordinary skill in the art would recognize small clearances or gaps exist along the corners 25 of the arrangement.
The column of tobacco proceeds to finishing section 16 is guided through a rod-forming arrangement 40, which includes a tongue 58. Rod-forming arrangement 40 is configured and arranged to fold the binder and wrapper web 30 and 34, respectively, longitudinally around the tobacco column and, in one form, employs a first garniture or short folder 64 and a second or finishing folder 66 for folding the wrapper web around the compressed tobacco column so as to form a continuous rod of tobacco for use in the production of cigars, the wrapper web provided from a source of wrapper material. An adhesive, which may be an adhesive such as PVA, is applied by adhesive applicator 59 to one lap edge of the wrapper web 34, and seals the lap joint by applying heat, by at least one heater 67 to set the adhesive.
To further demonstrate the folding or rolling operation, reference is made to FIG. 1 and to FIGS. 7-10, where cross-sections of a tobacco rod are presented to show the relative state of wrapper/binder folding or rolling at various positions along the length of rod-forming arrangement 40. As shown in FIG. 7, taken at Section 7-7 of FIG. 1 at the entrance to tongue 63, the folding process has yet to begin. As shown in FIG. 8, taken at Section 8-8 of FIG. 1 at the entrance to short folder 64, the folding operation has begun, with an upper lap edge of the wrapper/binder 30/34 extending substantially vertically and having had an application of glue applied thereto by adhesive applicator 59. Referring now to FIG. 9, taken at Section 9-9 of FIG. 1 at the entrance to the second folder 66, it may be seen that one side of the wrapper/binder 30/34 has been fully rolled over, while the upper lap edge of the wrapper/binder 30/34 still extends substantially vertically. Referring now to FIG. 10, taken at Section 10-10 of FIG. 1 at the exit of second folder 66, it may be seen that the tobacco rod has been fully formed and ready for heating to set the glue applied by adhesive applicator 67.
A continuous rod is thus produced and is carried by the garniture tube belt 42 through an optional air bearing arrangement (not shown). The rod then emerges from the garniture tube belt 42 and may pass through a weight scanner (not shown) and then through a diameter gauge (not shown) before being cut into discrete rod lengths by a cutter 68.
When forming tobacco rods, particularly when the tobacco is of the type frequently marketed as pipe tobacco, the tobacco tends to accumulate on the machine surfaces. In manufacturing operations, to mitigate the problems associated with this accumulation, opposing parts were designed to have greater clearances greater than a nominal clearance, which permitted the escape of tobacco during machine operation. The extra clearances allowed great amounts of tobacco to escape.
It has been discovered that the use of a hard ceramic coating that is heat stable, durable, and which also has a degree of wear resistance, to coat the parts of the rod making apparatus that come into contact with tobacco, reduces or eliminates tobacco accumulation on machine parts having surfaces that come into contact with tobacco, permitting closer clearances to be employed between many of the parts, including clearances 25, as shown in FIG. 5. Previously, clearances such clearances 25 were set to a dimension on the order of about 0.100 inches. Advantageously, the application of the hard ceramic coating disclosed herein permit the setting of such clearances to values of about 20 percent of their previous values, such as in this example to about 0.020 inches.
As may be appreciated, closer clearances enable improved tobacco utilization, since the escape of tobacco is reduced or minimized during the rod making operation. In operation, the resultant rod making machine is cleaner, faster, more consistent, more flexible, and more efficient than prior designs. As may be appreciated, such advantages can lead to the production of higher quality product.
One coating that has been developed is a non-stick ceramic poly-condensated silicone coating using an inorganic network of metal alkoxides and an organic network of polysilanes. Typically, the coating is applied using a sol-gel process. This coating is typically applied in two layers, where the base or first layer is typically a combination of polydimethylsiloxane in a matrix of mixed materials including organoalkoxysilane, silica sol and an alcoholic solvent. The second layer is usually applied to further enhance the non-stick properties, and change the surfaces color, by including fluoroalkoxysilanes along with polydimethylsiloxane and the matrix of mixed materials listed above. Such coatings are commercially available from Thermolon, Ltd under the trademark Thermolon™ and come in a number of varieties depending on the combination of polydimethylsiloxane, flouoalkoxysilanes, and the matrix materials. Thermolon™ coatings can generally withstand temperatures up to 750 degrees Fahrenheit indefinitely without any serious loss of performance.
Another coating having utility in the practice of the present invention is a polyceramic coating containing both polymeric and ceramic components to enable hard, durable surfaces with excellent release properties. A common tradename for one such product is Cerakote™, sold by NIC, where the polyceramic materials is mixed into a solvent and then applied as a sol-gel via spraying, brushing or wiping. Another such product is sold under the Ceraset™ trade name by KiON International. This type of coating is commonly used on products such as gun barrels, which also desire good release properties.
In one embodiment, the coating generally is comprised of a poly-condensated silicone or a polymeric silazane finish (commonly called Thermolon™) or a poly-ceramic finish (commonly branded under Ceraset™ and Cerakote™ brands). In alternate embodiments, the coating can include any suitable heat stable coating that is uncommonly hard, provides outstanding release properties and will adhere to the surfaces that come in contact with tobacco of a rod forming machine, as described herein.
Thermolon™ possesses excellent mechanical and chemical resistance properties that are retained to high temperatures. For example, Thermolon™ retains a tensile hardness value of 9 H, even up to 200° C. (or above). Additionally, the abrasion resistance of Thermolon™ (Reciprocal Abrasion Test; BS7069: 1988; 4.5 kg force; 3M 7447 Scotch-Brite abrasive pad) is excellent and has been found to withstand 32,000-59,000 cycles, depending upon the particular formulation. It is highly resistant to thermal degradation as well as attack by both organic and aqueous environments.
In one form, components having surfaces that contact the tobacco are coated with a material comprising a poly-condensated silicone or a polymeric silazane finish.
In one form, squeeze bars 60 and 62 are coated with a material comprising a poly-condensated silicone or a polymeric silazane finish. In another from, tongue 58 is also coated with a material comprising a poly-condensated silicone or a polymeric silazane finish. In still another form, transition piece 56 is also coated with a material comprising a poly-condensated silicone or a polymeric silazane finish. In still yet another form, short folder 64 and, optionally, a second folder 66 for folding a wrapper material around the compressed tobacco so as to form a continuous rod of tobacco are coated with a material comprising a poly-condensated silicone or a polymeric silazane finish. With respect to the foregoing, the poly-condensated silicone or polymeric silazane finish may be utilized along surfaces that come into contact with tobacco.
It is contemplated that additional components of apparatus 10 may be coated with a poly-condensated silicone or a polymeric silazane finish. For example, the vibratory waterfall feeder 20 and/or the tobacco feed section 12 may be coated with a poly-condensated silicone or a polymeric silazane finish. In some embodiments, the conveyor belt guide 70, which lower conveyor belt 24 rides along, may also be coated with a poly-condensated silicone or a polymeric silazane finish. In addition, it is contemplated that the transition piece 56 (see FIG. 4) be coated with a poly-condensated silicone or a polymeric silazane finish. Use of with a poly-condensated silicone or a polymeric silazane finish along the conveyor belt guide 70 avoids accumulation of material between the conveyor belt guide 70 and the belt 24, which can otherwise lead to jamming of the belt. The belt has the tendency to pick up minute pieces of tobacco during its course of travel.
In one form, apparatus 10 employs a programmable logic controller (PLC unit) to control the formation of machine-made tobacco rods. Suitable PLC units are available from a number of sources, including Allen-Bradley, a division of Rockwell Automation of Milwaukee, Wis. Vibratory waterfall feeder 20 is fed by a metering belt (not shown) which may be adjusted proportionally to the rod-making speed by signals received by PLC unit. In one form, there is a sensor provided to monitor rod-making speed and the PLC unit is programmed to dynamically adjust the metering belt in response to changes in rod-making speed.
Various signals, which may include a signal representing the rod diameter, an indication of the tobacco temperature obtained from a temperature sensor that may be located in a tobacco hopper, or in the chamber near the trimmer are fed to the PLC unit. Suitable rod diameter gauges may be as described in U.S. Pat. No. 2,952,262, the contents of which are hereby incorporated by reference in their entirety.
In operation, a tobacco column is carried on the gravity conveyor 24 and drawn by the lower and upper belts 24 and 50, respectively. between squeeze bars 60 and 62 to garniture tube belt 42. A signal indicative of the firmness of the finished rod may be used to control the trimmer height preferably after correction to compensate for moisture variations so that the trimmer is controlled in response to the “dry firmness.” A control motor may drive the trimmer up and down around an average trimmer height H_avg, in response to control signals from the microprocessor 66. The actual height H of the trimmer, determined by a trimmer position sensor (not shown), is fed to the PLC unit to provide a signal corresponding to the actual resistance of the part of the filler column that remains after trimming.
From the data received, the PLC unit may calculate characteristics of the finished product and display such information on a display unit. PLC unit and display unit may be housed within a cabinet, which may also include a control panel, the combination of which forms a control system. The control panel may provide the ability to control various functions, including the heaters, glue applicator, machine start-up, system power, etc. Suitable control systems may be obtained from Jewett Automation of Richmond, Va. In one form, control system is a Jewett Automation Model Q75.
Alternatively, or in addition, information can be fed to a central management control system either for instant display or for storage, or for both.
Additionally details concerning process controls and control schemes useful in the operation and control of apparatus 10 are provided in U.S. Pat. No. 4,567,752, the contents of which are hereby incorporated by reference in their entirety.
In another aspect, provided is a method for the formation of machine-made tobacco rods for use in the production of cigars from tobacco having a tacky material combined therewith. The method includes providing a stream of tobacco in a substantially uniform format; receiving and compressing the stream of tobacco between a pair of transfer and compression belts, the transfer and compression driven by a plurality of pulleys; compressing the tobacco in a direction perpendicular to the pair of transfer and compression belts between a pair of squeeze bars, the pair of squeeze bars coated with a poly-condensated silicone or a polymeric silazane finish; conveying the compressed tobacco downstream to a tongue, the tongue coated with a poly-condensated silicone or a polymeric silazane finish; providing a wrapper material from a source of wrapper material; and folding the wrapper material around the compressed tobacco so as to form a continuous rod of tobacco for use in the production of cigars.
In one form, the step of folding the wrapper material around the compressed tobacco so as to form a continuous rod of tobacco for use in the production of cigars utilizes a short folder coated with a poly-condensated silicone or a polymeric silazane finish. In another form, each of the plurality of pulleys is coated with a poly-condensated silicone or a polymeric silazane finish.
In one aspect, provided is a method of decreasing tobacco waste during the formation of machine-made tobacco rods for use in the production of cigars from tobacco having a tacky material combined therewith, The method includes the steps of coating a plurality of components of a cigar rod-making machine with a poly-condensated silicone or a polymeric silazane finish; reducing at least one gap between at least one of the plurality of components with an adjacent component of the cigar rod-making machine to reduce the possibility that the tobacco escapes through the gap.
In one form, the method further includes the step of operating the cigar rod-making machine to produce cigar rods from the tobacco having a tacky material combined therewith, wherein tobacco wasted in the production of cigar rods is decreased.
In another form, the tobacco wasted in the production of cigar rods is decreased by at least 25%. In yet another form, the tobacco wasted in the production of cigar rods is decreased by at least 50%. In still yet another form, the tobacco wasted in the production of cigar rods is decreased by at least 80%. Tobacco waste is reduced by decreasing tolerance gaps between components coated with a poly-condensated silicone or a polymeric silazane finish by at least 20%, or at least 30%, or at least 40% or more.
In a further form, the plurality of components are selected from a pair of squeeze bars for compressing the tobacco, one or more pulleys for advancing transfer and/or compression belts, a tongue for guiding the tobacco, a short folder, or any combination thereof.

Examples

Testing was conducted to evaluate the productivity over an extended period of time for an apparatus designed in accordance herewith. The focus of the evaluation was on machine runtime v. downtime, material and filler waste and non-conforming product. Performance was assessed with respect to productivity (e.g.: target rod weight, speed in rods per minute, production in terms of trays of product and machine interference downtime).
Performance was assessed with respect to waste and non-conforming product (e.g.: loose wrapper and binder, loose filler, long-ends (i.e., rod-outs) and wrapper and binder cores).
The evaluation was conducted with the inventive rod maker and control rod maker producing product to a target rod weight of 3,300 mg. The inventive rod maker was running at a speed of 1,100 cigars per minute while the control rod maker was operating at a speed of 800 cigars per minute.
Notable causes of machine downtime during the evaluation include: tongue adjustments, a blade break and change, and cleaning of cutter gears.
As noted above, waste was collected from the inventive rod maker and a control rod maker.
As indicated above, the use of Thermolon™ to coat critical parts has been found to permit the establishment of tighter part-to-part clearances, minimizing the escape of tobacco during the rod formation operation. Thus, through material selection and the setting of proper clearances, together with the integration of a PLC control system, improved performance was achieved.
While the present inventions have been described in connection with a number of exemplary forms, and implementations, the present inventions are not so limited, but rather cover various modifications, and equivalent arrangements, which fall within the purview of the present claims. For example, it is contemplated that the subject matter disclosed herein would have utility in the formation of any wrapped or formed body produced from a tacky shredded material, such as shredded herbal material, pouches of tacky shredded material, moist snuff or the like.

Claims

What is claimed:

1. In the formation of machine-made tobacco rods for use in the production of smoking articles from a tobacco having a tacky material combined therewith, a method of decreasing tobacco waste, comprising the steps of:

a) providing a plurality of components of a rod-making machine, the plurality of components coated with a poly-condensated silicone or a polymeric silazane finish; and

b) reducing at least one clearance gap between at least one of the plurality of components with an adjacent component of the rod-making machine to reduce the amount of tobacco escaping through the gap.

2. The method of claim 1, further comprising the step of:

c) operating the rod-making machine to produce rods from the tobacco having a tacky material combined therewith, wherein tobacco wasted in the production of cigar rods is decreased.

3. The method of claim 2, wherein tobacco wasted in the production of cigar rods is decreased by at least 25%.

4. The method of claim 3, wherein tobacco wasted in the production of cigar rods is decreased by at least 50%.

5. The method of claim 4, wherein tobacco wasted in the production of cigar rods is decreased by at least 80%.

6. The method of claim 2, wherein the plurality of components are selected from those components having surfaces that contact the tobacco.

7. The method of claim 6, wherein the plurality of components are selected from a pair of squeeze bars for compressing the tobacco, one or more pulleys for advancing transfer and/or compression belts, a tongue for guiding the tobacco, a short folder, a transition piece or any combination thereof.

8. The method of claim 6, wherein the plurality of components are selected from a vibratory waterfall feeder and/or a tobacco feed section.

9. An apparatus for the formation of machine-made tobacco rods for use in the production of cigars from tobacco having a tacky material combined therewith, the apparatus comprising:

(a) a lower conveyor belt and an upper compression belt for receiving and compressing the stream of tobacco, said lower conveyor belt and upper compression belt driven by a plurality of pulleys;

(b) a pair of squeeze bars for compressing the tobacco in a direction perpendicular to said pair of transfer and compression belts, said pair of squeeze bars coated with a poly-condensated silicone or a polymeric silazane finish;

(c) a tongue for receiving the compressed tobacco, said tongue coated with a poly-condensated silicone or a polymeric silazane finish; and

(d) a short folder for folding a wrapper material around the compressed tobacco so as to form a continuous rod of tobacco for use in the production of cigars, said wrapper material provided from a source of wrapper material, said short folder coated with a poly-condensated silicone or a polymeric silazane finish.

10. The apparatus of claim 9, further comprising a tobacco feed section for providing a stream of tobacco in a substantially uniform format.

11. The apparatus of claim 10, further comprising a vibratory waterfall feeder positioned downstream of said tobacco feed section for receiving the stream of tobacco from said tobacco feed section.

12. The apparatus of claim 11, wherein the vibratory waterfall feeder and/or the tobacco feed section are coated with a poly-condensated silicone or a polymeric silazane finish.

13. The apparatus of claim 9, wherein each of said plurality of pulleys are coated with a poly-condensated silicone or a polymeric silazane finish.

14. The apparatus of claim 13, further comprising a source of binder material for wrapping the compressed tobacco prior to further wrapping with the wrapper material.

15. The apparatus of claim 10, further comprising a glue applicator for applying glue to the wrapper material prior to folding the wrapper material around the compressed tobacco.

16. A method for the formation of machine-made tobacco rods for use in the production of cigars from tobacco having a tacky material combined therewith, the method comprising:

(a) providing a stream of tobacco in a substantially uniform format;

(b) receiving and compressing the stream of tobacco between a lower conveyor belt and an upper compression belt, the lower conveyor belt and upper compression belt driven and guided by a plurality of pulleys;

(c) compressing the tobacco in a direction perpendicular to the pair of transfer and compression belts between a pair of squeeze bars, the pair of squeeze bars coated with a poly-condensated silicone or a polymeric silazane finish;

(d) conveying the compressed tobacco downstream to a tongue, the tongue coated with a poly-condensated silicone or a polymeric silazane finish;

(e) providing a wrapper material from a source of wrapper material; and

(f) folding the wrapper material around the compressed tobacco so as to form a continuous rod of tobacco for use in the production of cigars.

17. The method of claim 16, wherein said step of folding the wrapper material around the compressed tobacco so as to form a continuous rod of tobacco for use in the production of cigars utilizes a short folder coated with a poly-condensated silicone or a polymeric silazane finish.

18. The method of claim 16, wherein each of the plurality of pulleys are coated with a poly-condensated silicone or a polymeric silazane finish.

19. The method of claim 16, wherein the step of providing a stream of tobacco in a substantially uniform format employs a vibratory waterfall feeder and a tobacco feed section that are coated with a poly-condensated silicone or a polymeric silazane finish.

20. In the machine formation of a formed body from a tacky shredded material, a method of decreasing the waste of the tacky shredded material, comprising the steps of:

a) providing a plurality of forming machine components, the plurality of components coated with a poly-condensated silicone or a polymeric silazane finish and characterized by a resistance to collecting the tacky shredded material and having a degree of wear resistance; and

b) reducing at least one clearance gap between at least one of the plurality of components with an adjacent component of the forming machine to reduce the possibility that the tacky shredded material escapes through the gap.

21. A method of forming a rod from a shredded material and a wrapper, said shredded material including a tacky constituent, said method comprising:

establishing a moving column of the shredded material;

compressing said column by moving said column along opposing converging guides coated with a poly-condensated silicone or a polymeric silazane finish;

forming the rod by drawing said compressed column and the wrapper through a folding surface coated with a poly-condensated silicone or a polymeric silazane finish.

22. The method of claim 21, wherein said establishing step includes moving a lower endless belt adjacent a feeder while guiding said lower belt with a guide plate coated with a poly-condensated silicone or a polymeric silazane finish.

23. The method of claim 22, wherein said compressing step includes compressing the column with convergent, opposing endless belts.

24. The method of claim 23, further comprising abating accumulation of shredded material by providing a guide piece coated with a poly-condensated silicone or a polymeric silazane finish at a transition space between sets of convergent, opposing endless belts.

25. An apparatus capable of forming a rod from a shredded material and a wrapper, said shredded material including a tacky constituent, said apparatus comprising:

a feeder that establishes a moving column of the shredded material;

opposing converging guides that compress said column as said column moves along said opposing converging guides, said opposing converging guides coated with a poly-condensated silicone or a polymeric silazane finish;

a folding surface that forms the rod as said compressed column and the wrapper are drawn through said folding surface, said folding surface coated with a poly-condensated silicone or a polymeric silazane finish.

26. The apparatus of claim 25, wherein said feeder includes moving a lower endless belt and a guide plate that guides said lower endless belt, said guide plate coated with a poly-condensated silicone or a polymeric silazane finish.

27. The apparatus of claim 26, wherein said opposing converging guides cooperate with convergent, opposing endless belts to compress the column.

28. The apparatus of claim 27, further comprising a transition guide at a transition space between sets of convergent, opposing endless belts, said transition guide abating accumulation of shredded material and coated with a poly-condensated silicone or a polymeric silazane finish.