WO2024153624A1 - Traitement de tabac - Google Patents

Traitement de tabac Download PDF

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Publication number
WO2024153624A1
WO2024153624A1 PCT/EP2024/050880 EP2024050880W WO2024153624A1 WO 2024153624 A1 WO2024153624 A1 WO 2024153624A1 EP 2024050880 W EP2024050880 W EP 2024050880W WO 2024153624 A1 WO2024153624 A1 WO 2024153624A1
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WO
WIPO (PCT)
Prior art keywords
tobacco
diet
dry ice
process according
temperature
Prior art date
Application number
PCT/EP2024/050880
Other languages
English (en)
Inventor
Tamas MARSI
Rodrigo DORFEY
Pamela LIMA
Constanza GALLO
Jason SYMONDS
Agustin PIAGGIO
Batir ABDURAHMANOV
Original Assignee
British American Tobacco Exports Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Publication date
Application filed by British American Tobacco Exports Limited filed Critical British American Tobacco Exports Limited
Publication of WO2024153624A1 publication Critical patent/WO2024153624A1/fr

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Classifications

    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24B—MANUFACTURE OR PREPARATION OF TOBACCO FOR SMOKING OR CHEWING; TOBACCO; SNUFF
    • A24B3/00—Preparing tobacco in the factory
    • A24B3/14—Forming reconstituted tobacco products, e.g. wrapper materials, sheets, imitation leaves, rods, cakes; Forms of such products
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24B—MANUFACTURE OR PREPARATION OF TOBACCO FOR SMOKING OR CHEWING; TOBACCO; SNUFF
    • A24B15/00—Chemical features or treatment of tobacco; Tobacco substitutes, e.g. in liquid form
    • A24B15/10—Chemical features of tobacco products or tobacco substitutes
    • A24B15/12—Chemical features of tobacco products or tobacco substitutes of reconstituted tobacco
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24B—MANUFACTURE OR PREPARATION OF TOBACCO FOR SMOKING OR CHEWING; TOBACCO; SNUFF
    • A24B3/00—Preparing tobacco in the factory
    • A24B3/18—Other treatment of leaves, e.g. puffing, crimpling, cleaning
    • A24B3/182—Puffing
    • A24B3/185—Puffing by impregnating with a liquid and subsequently freezing and evaporating this liquid

Definitions

  • the present invention relates to a process and in particular a process for the treatment of dry ice expanded tobacco (DIET).
  • DIET dry ice expanded tobacco
  • tobacco material After harvesting, tobacco material can be cured to prepare the leaf for consumption.
  • the tobacco material may be further treated, for example by aging or fermentation, to enhance the organoleptic properties of the tobacco.
  • these processes can be lengthy and the quality of the resulting tobacco material can be variable.
  • Treatments to enhance or add flavours and aromas to the tobacco material at a later stage of tobacco processing often involve the addition of one or more additive(s) to the tobacco and can require additional processing steps and equipment, which can be costly and timeconsuming.
  • a process for treating dry ice expanded tobacco (DIET) which has been enclosed within a moisture-retaining material, the process comprising exposing the tobacco to an ambient processing temperature of above 45°C, wherein the tobacco has a packing density of 60 to 160 kg/m 3 at the start of the process and has a moisture content of between about 10% and 23% before and during treatment.
  • DIET dry ice expanded tobacco
  • the process may be used to produce a tobacco with desirable organoleptic properties.
  • the expanded DIET may optionally be suitable for use in a combustible aerosol delivery system.
  • a process for producing DIET for use in a combustible aerosol delivery system, the process comprising exposing DIET which has been enclosed within a moistureretaining material to an ambient processing temperature of above 45°C, wherein the tobacco has a packing density of 60 to 160 kg/m 3 at the start of the process and has a moisture content of between about 10% and 23% before and during treatment.
  • the process may be used to produce a tobacco with desirable organoleptic properties.
  • the processes of the first or second aspect may comprise enclosing or securing the tobacco within the moisture-retaining material before exposing the tobacco to the specified conditions.
  • treated dry ice expanded tobacco is provided which is obtainable by the process of the first or second aspects.
  • a fourth aspect provides treated dry ice expanded tobacco produced according to (or obtained by) the process of the first or second aspects.
  • a fifth aspect provides a component for use in a combustible aerosol provision system, the component comprising the treated dry ice expanded tobacco material of the third or fourth aspects.
  • a sixth aspect provides an article for use in a combustible aerosol provision system, the article including the component of the fifth aspect.
  • a further aspect provides an aerosol provision system comprising the treated dry ice expanded tobacco of the third or fourth aspects, the component of the fifth aspect or the article of the sixth aspect.
  • the processes described herein may also further comprise incorporating treated dry ice expanded tobacco material into a combustible aerosol provision system, or component or article therefor.
  • the processes described herein may further comprise incorporating the treated dry ice expanded tobacco material into a blend.
  • the blend may be suitable for use in a combustible aerosol provision system, or component or article therefor. Suitable amounts of the treated dry ice expanded tobacco material in the blend are set out below.
  • a further aspect provides the use of the treated dry ice expanded tobacco material of the third or fourth aspects for the manufacture of a component for use in a combustible aerosol provision system.
  • the treated DIET may be used to make a tobacco extract.
  • a further aspect provides a tobacco extract manufactured from the DIET of the third or fourth aspects.
  • Figure 1 is a process flow diagram for the manufacture of dry ice expanded tobacco
  • Figure 2 shows a cross section through a tobacco leaf before (top) and after (bottom) dry ice expansion.
  • the scale bar (centre, bottom) of each image corresponds to a distance of 100 microns.
  • Figure 3 is a process flow diagram for the manufacture of expanded stem tobacco.
  • Figure 4 is a photograph in which treated DIET is being passed through a set of doffers.
  • Expanded tobacco material is tobacco material that has been subjected to an expansion process. Expansion involves increasing the volume of the cell structure of the tobacco material which may result in an increase in the area and spacing between any fibres present in the tobacco material. After being subjected to the expansion process, the tobacco material has a higher fill value, but lower density, than the tobacco material prior to the expansion process. Expanded tobacco may be blended with other types of tobacco, for example to provide smoking articles having a lower overall weight than convention articles. Reducing the overall weight can provide numerous advantages, such as reduced transportation costs. Furthermore, reducing the weight of articles may also have a positive impact on the environment because less energy may be required to transport articles. In addition, consumers may prefer to carry and use a lighter-weight article.
  • Types of expanded tobacco include dry ice expanded tobacco and expanded stem. Expanded stem is formed by steam expansion of stem tobacco. However, expanded tobacco materials may compromise the organoleptic properties of tobacco blends containing them, which may limit the amount of the expanded tobacco material that can be included in the blends whilst maintaining an acceptable taste profile.
  • the present invention relates to a process for the treatment of dry ice expanded tobacco (DIET).
  • DIET dry ice expanded tobacco
  • the treated DIET may be for use in a combustible aerosol delivery system.
  • the treatment favourably changes the organoleptic properties of the DIET.
  • the inventors have, however, found that these desirable changes in organoleptic properties are not observed when the same treatment is performed on other types of expanded tobacco.
  • no significant change in taste profile between treated and untreated expanded stem i.e. expanded stem tobacco before and after a treatment process as described herein
  • a change in taste profile was found between treated and untreated DIET (i.e. DIET before and after a treatment process as described herein). That is, the inventors have surprisingly found that the process of the invention is particularly suitable for improving the organoleptic properties of DIET, whereas it is not suitable for improving the organoleptic properties of expanded stem.
  • the favourable change in the organoleptic properties of the DIET tobacco means that the treated tobacco can be added to tobacco blends (for example for use in a smoking article) in higher quantities than untreated DIET tobacco without compromising the organoleptic properties of the tobacco blends.
  • the inventors have also found that the high fill value of the dry ice expanded tobacco is maintained during the process of the invention.
  • the fill value of the dry ice expanded tobacco may even increase during the process.
  • the term ‘treated tobacco’ refers to tobacco that has undergone the treatment process described herein, and the term ‘untreated tobacco’ refers to tobacco that has not undergone the treatment process.
  • the tobacco used in the process of the invention is dry ice expanded tobacco (DIET). Tobacco undergoes a number of steps prior to consumption by the consumer. On the field the following steps are usually carried out by the farmer: seeding; transplanting; growing; harvesting; and curing.
  • DIET dry ice expanded tobacco
  • Tobacco is generally cured after harvesting to reduce the moisture content of the tobacco, usually from around 80% to around 20% or lower. Tobacco can be cured in a number of different ways, including air-, fire-, flue- and sun-curing. During the curing period, the tobacco undergoes certain chemical changes and turns from a green colour to yellow, orange or brown. The temperature, relative humidity and packing density are carefully controlled to try to prevent houseburn and rot, which are common problems encountered during curing.
  • GLT Green Leaf Threshing
  • the stem may be removed from the lamina. This may be done by threshing, in which the midribs and partially the lamina ribs are separated from the lamina by machine threshing.
  • An alternative way to remove the stem from lamina is manually, with the so-called ‘hand stripping’ process.
  • tobacco may be ‘butted’, which means that the thick part of the stem is cut, while the rest of the tobacco leaf remains integral.
  • the tobacco may be further processed to enhance its taste and aroma.
  • Aging and fermentation are known techniques for enhancing the taste and aroma of tobacco. These processes can be applied to tobacco materials such as threshed lamina, hand-stripped lamina, butted lamina and/or whole leaf tobacco.
  • Tobaccos that undergo aging include Oriental, flue-cured and air-cured tobaccos.
  • the tobacco might be stored generally at temperatures of around 20°C to around 40°C and relative humidities present at the respective country of origin/aging or under controlled warehouse conditions for around 1 to 3 years. It is important that the moisture content of the tobacco is kept at a relatively low level during aging, for example up to around 10-13%, as mould will form in tobacco with higher moisture content.
  • Fermentation is a process that is applied to particular tobaccos, including dark aircured tobacco, cured Oriental tobacco and cigar tobacco, to give the tobacco a more uniform colour and to change the aroma and taste. Fermentation is generally not applied to flue-cured and light air-cured tobacco. Fermentation is also generally not applied to DIET tobacco.
  • the fermentation parameters vary depending on the type of tobacco that is undergoing fermentation. Generally, the fermentation moisture is either similar to the moisture content of the tobacco when it has been received from the farmer (around 16-20%), or the tobacco is conditioned to a slightly higher moisture content. Care has to be taken to avoid the production of different rots, which occur when the tobacco is fermented at a moisture content that is too high.
  • the duration of the fermentation period can vary, ranging from several weeks to several years.
  • fermentation involves the treatment of tobacco in large volumes and is applied to whole leaf, with subsequent removal of the stem after process.
  • the tobacco can be arranged into large piles, which is then turned at intervals to move the tobacco at the periphery into the centre of the pile.
  • the tobacco is placed into chambers with a volume of several square meters. Treatment of such large volumes of tobacco can be cumbersome and/or time-consuming.
  • fermentation relies on the activity of microorganisms to effect changes in the tobacco material and the fermentation conditions, including temperature and moisture content of the tobacco, are selected to enhance the microbiological activity during fermentation. For example, during fermentation treatment temperatures must typically be controlled within the range of 38-40 °C. In most, if not all, cases the fermentation of tobacco relies upon microorganisms already present in the tobacco material. However, suitable microorganisms could potentially be added to the tobacco material at the start of the fermentation process.
  • the tobacco is transported to other locations to be further processed, for example before it is incorporated into a tobacco-containing product.
  • the tobacco is generally unpacked, conditioned, blended with other tobacco styles and/or types and/or varieties, cut, dried, blended with other tobacco materials, and handed over to the cigarette manufacturing department.
  • Tobacco may additionally or alternatively be treated with additives to improve or enhance the flavour and aroma of the tobacco.
  • additives to improve or enhance the flavour and aroma of the tobacco.
  • this requires additional processing steps and apparatus, making the tobacco preparation process more lengthy and often more costly.
  • Additives are generally applied in the location at which the smoking article is being produced, such as a cigarette factory, although the point at which additives are applied can vary.
  • the process of treating tobacco material as described herein produces a dry ice expanded tobacco material with desirable organoleptic properties within a period of time that may be shorter than the more traditional techniques such as fermentation and aging and without the addition of flavour or aromatising additives.
  • the process of the present invention involves no fermentation or essentially no fermentation. This may be demonstrated by the presence of little or no microbial content of the tobacco material at the end of the process. Thus, in one embodiment the microbial content of the tobacco material at the end of the process is lower than the microbial content of the tobacco material at the start of the process.
  • the process of treating dry ice expanded tobacco material as described herein produces a tobacco with an enhanced flavour profile or enhanced organoleptic properties (compared to the flavour profile of dry ice expanded tobacco which has not been treated or which has been treated using only conventional curing processes). This means that there is a reduction in off-notes or irritants, whilst retaining the taste characteristics of the tobacco as would be seen following conventional curing.
  • the terms “enhance” or “enhancement” are used in the context of the flavour or organoleptic properties to mean that there is an improvement or refinement in the taste or in the quality of the taste, as identified by expert smokers. This may, but does not necessarily, include a strengthening of the taste.
  • the process of treating dry ice expanded tobacco material as described herein produces a tobacco material wherein at least one undesirable taste or flavour characteristic has been reduced. For example, dryness and irritant off-notes may be reduced.
  • the process described herein may be used to enhance the organoleptic properties of a dry ice expanded tobacco starting material which has poor organoleptic (e.g. taste) properties. It has been found that at least one effect that the processing has on the dry ice expanded tobacco material is the removal or reduction of organoleptic factors that have a negative impact on the overall organoleptic properties of the tobacco material. In some embodiments, the process may also result in the increase of positive organoleptic properties.
  • the process of treating dry ice expanded tobacco may be adjusted to produce a treated material with particular selected organoleptic characteristics. This may, for example, involve the adjustment of one or more of the parameters of the process.
  • the process of treating dry ice expanded tobacco material as described herein transforms the flavour profile of the tobacco (compared to the flavour profile of tobacco which has not been treated or which has been treated using only conventional curing processes). This means that there is a significant change in the organoleptic properties of the tobacco following the processing, so that the taste characteristics of the tobacco are changed compared to those of untreated DIET tobacco.
  • the terms “transform” or “transformation” are used in the context of the flavour or organoleptic properties to mean that there is change from one overall taste or sensory character to another, as identified by expert smokers. This may include an improvement and/or refinement in the taste or in the quality of the taste.
  • the processing has the effect of not only reducing or removing organoleptic factors that have a negative effect, but also introducing or increasing organoleptic factors that have a positive effect.
  • the process described herein leads to an increase in the products of the Maillard Reaction, many of which are known to contribute to desirable organoleptic properties.
  • organoleptic properties of the tobacco material may be reference to the organoleptic properties of the tobacco material itself, for example when used orally by a consumer. Additionally or alternatively, the reference is to the organoleptic properties of smoke produced by combusting the tobacco material, or of vapour produced by heating the tobacco material. In some embodiments, the treated tobacco material affords a tobacco product including said tobacco material with desirable organoleptic properties when said product is used or consumed.
  • the tobacco material used in the disclosure is dry ice expanded tobacco.
  • tobacco material includes any part and any related by-product, such as for example the leaves or stems, of any member of the genus Nicotiana.
  • the tobacco material for use in the present invention is preferably from the species Nicotiana tabacum.
  • any type, style and/or variety of dry ice expanded tobacco may be treated.
  • tobacco which may be used include but are not limited to Virginia, Burley, Oriental, Comum, Amarelinho and Maryland tobaccos, and blends of any of these types.
  • the skilled person will be aware that the treatment of different types, styles and/or varieties will result in tobacco with different organoleptic properties.
  • the tobacco material comprises lamina tobacco material.
  • the tobacco may comprise from about 70% to 100% by weight lamina material.
  • the tobacco may comprise from about 80% to 100% by weight lamina material, such as from about 90 to about 99% by weight lamina material.
  • the tobacco material may comprise up to 50%, up to 60%, up to 70%, up to 80%, up to 90%, or up to 100% by weight lamina tobacco material. In some embodiments, the tobacco material comprises up to 100% by weight lamina tobacco material. In other words, the tobacco material may comprise substantially entirely or entirely lamina tobacco material.
  • the tobacco material comprises, consists essentially of, or consists of, lamina tobacco, such as a lamina tobacco comprising lamina Virginia tobacco.
  • lamina tobacco may be selected from Virginia or a blend of Virginia and Burley tobacco.
  • the weight ratio of the Virginia to Burley may be from 1:10 to 10:1 , such as from 1:5 to 5:1 , 1 :2 to 2:1, 1:1.5 to 1.5:1 or 1.2:1 to 1:1.2.
  • the tobacco material may comprise at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, or at least 95% by weight lamina tobacco material.
  • the lamina may be in whole leaf form or cut form.
  • the tobacco material (such as lamina tobacco) is in cut form. Using cut tobacco reduces the time needed to impregnate/permeate the tobacco with liquid carbon dioxide during the dry ice expansion.
  • the DIET tobacco material comprises stem tobacco material.
  • the tobacco may comprise up to about 20% by weight of stem material, such as up to about 15% by weight of stem.
  • the tobacco material may comprise 1-20% by weight of stem material and 80-99% by weight of lamina tobacco, such as 5-15% by weight of stem material and 85-95% by weight of lamina material.
  • Pre-prepared DIET may be treated according to the process of the invention.
  • DIET is commercially available.
  • the process may comprise dry ice expansion of a tobacco material to provide the DIET, and then treating the DIET as described herein.
  • dry ice expansion involves permeating (or impregnating) the tobacco with liquid carbon dioxide under pressure, for example by submerging and soaking the tobacco in liquid carbon dioxide. Excess liquid and/or gaseous carbon dioxide can be recovered for reuse, for example by draining the liquid.
  • the process may comprise converting the liquid carbon dioxide within the tobacco into solid carbon dioxide (dry ice), for example by reducing the pressure.
  • dry ice solid carbon dioxide
  • the solid carbon dioxide is then subjected to conditions under which the solid carbon dioxide vaporizes (or under which the solid carbon dioxide undergoes sublimation to form gaseous carbon dioxide), thereby causing the tobacco material to expand.
  • the tobacco material comprising the solid carbon dioxide can be rapidly heated as set out below. After warming, the dry ice sublimates to form gaseous carbon dioxide, which forces the tobacco to expand.
  • a suitable method of dry ice expansion may comprise impregnating the cell structure of tobacco with liquid carbon dioxide.
  • the tobacco that is impregnated is cut tobacco.
  • Suitable conditions for this impregnation step may comprise contacting the tobacco material in an impregnator vessel with liquid carbon dioxide at a temperature of -40 to -10 °C, such as -25 to -15 °C, for a period of around 1-10 minutes, such as 2-8 or 3-7 minutes, under pressure.
  • the pressure may be for example 435 psig (3000 kPa).
  • Suitable cut widths are disclosed below in the description of Figure 1.
  • the tobacco material may have a moisture content of 10-40% such as 15-35%, or 20-30%.
  • the process typically then comprises reducing the pressure within the impregnator vessel sufficiently to cause solidification of the liquid carbon dioxide within the cell structure.
  • the pressure may be reduced to atmospheric pressure (1 atm).
  • the process may then involve rapidly heating the tobacco to sublime the solid carbon dioxide in the tobacco cells, thereby causing the tobacco to expand. This rapid heating may be carried out by introducing the tobacco material comprising solid carbon dioxide into a gas stream having a temperature of from 250 to 400 °C, such as 300-360 °C, or about 330 °C.
  • the process may then comprise hydrating the dry ice expanded tobacco to the desired initial moisture content for further treatment by the process of the invention.
  • Figure 1 depicts a suitable exemplary process for preparing dry ice expanded tobacco.
  • Bales of tobacco material are sliced and then the bales are conditioned using water and steam.
  • the tobacco material can be any of the tobacco materials described herein.
  • Lamina tobacco in particular lamina Virginia tobacco, is particularly preferred.
  • stem tobacco may be used in addition to lamina.
  • the conditioned tobacco material is blended with other conditioned tobacco materials or mixed before being fed into a cutter.
  • the cutter cuts the tobacco material at 25 to 28 cuts per inch (CPI).
  • a cut width of 25 CPI is particularly preferred, although other cut widths could be used. Cutting the tobacco material increases its surface area and thus reduces the time it takes to become impregnated with liquid during the impregnation step. These cut widths may also increase the fill value of the final material.
  • the material After wetting the cut material and blending the wet cut material, the material has a moisture content of around 26%. This material is then fed into an impregnator vessel, which is subsequently charged with carbon dioxide at a temperature of -20 °C for around 6 minutes under pressure. These conditions ensure that the carbon dioxide stays in a liquid form and has enough time to penetrate and be absorbed into the tobacco material. Following on from this, the impregnated tobacco material is fed into a sublimator, the pressure is reduced to allow the liquid carbon dioxide to solidify, the impregnated tobacco material is then heated in a gas stream at a temperature of 330 °C. This results in rapid volatilisation of the moisture and carbon dioxide in the tobacco material, which causes it to expand.
  • gas temperatures may be used.
  • the gas temperature may be between about 250 °C and about 400 °C or more.
  • the maximum temperature is preferably below the combustion temperature of the tobacco material. High temperatures may improve the rate of expansion and thus the efficiency of the process.
  • the fill value of the tobacco material may also be controlled by changing the temperature. Increasing the temperature may lead to more moisture being driven off from the material and thus a higher fill value of the final material. Conversely, using lower temperatures may decrease the fill value of the final material.
  • the high gas temperatures can be achieved by any suitable means (e.g. by heating air using a hot plate or burner).
  • the tobacco material at the end of the sublimation is relatively dry and has a moisture content of around 6%.
  • the moisture content is increased to around 12% to 14% (the target is often 13.6%) by hydrating it in a reordering cylinder to produce the final expanded tobacco material.
  • the expanded material may have a fill value of at least about 6 cm 3 /g.
  • moisture When referring to “moisture” it is important to understand that there are widely varying and conflicting definitions and terminology in use. It is common for “moisture” or “moisture content” to be used to refer to water content of a material but in relation to the certain industries, such as the tobacco industry, it is necessary to differentiate between “moisture” as water content and “moisture” as oven volatiles.
  • Water content is defined as the percentage of water contained in the total mass of a solid substance.
  • Volatiles are defined as the percentage of volatile components contained in the total mass of a solid substance. This includes water and all other volatile compounds.
  • Oven dry mass is the mass that remains after the volatile substances have been driven off by heating. It is expressed as a percentage of the total mass.
  • Oven volatiles (OV) are the mass of volatile substances that were driven off.
  • Moisture content may be measured as the reduction in mass when a sample is dried in a forced draft oven at a temperature regulated to 110°C ⁇ 1°C for three hours ⁇ 0.5 minutes. After drying, the sample is cooled in a desiccator to room temperature for approximately 30 minutes, to allow the sample to cool.
  • references to moisture content herein are references to oven volatiles (OV).
  • Figure 2 shows a cross section through a tobacco leaf before (top) and after (bottom) dry ice expansion.
  • the scale bar (centre, bottom) of each image corresponds to a distance of 100 microns. The expansion of the tobacco material during the dry ice expansion process can be seen from a comparison of these images.
  • expanded stem which may also be referred to as expanded stem or steam treated stem (STS)
  • STS steam treated stem
  • Figure 3 illustrates one such process for expanding tobacco stem.
  • Tobacco is loaded into a feeder.
  • the tobacco stem can be derived from any of the varieties of tobacco described herein.
  • the moisture content of the stem is around 34%.
  • the mixture is then blended with stem from other batches and/or mixed thoroughly, at which point the stem has a moisture content of between around 30% and around 40%, such as around 36%.
  • the material is then cut to ensure the portions of stem are of consistent dimensions. This cutting may help to further increase the fill value of the material. Water is then applied to the cut stem to increase its moisture content to between about 35% and about 45%.
  • the relatively high moisture levels attained in this step help to increase the expansion of the stem during the subsequent expansion steps.
  • the material is subjected to steam treatment at temperatures in excess of 100 °C (e.g. using steam or superheated steam).
  • steam treatment e.g. using steam or superheated steam.
  • the steam can be applied at a rate of at least 200 kg/hr such as greater than 300 kg/hr or greater than 350 kg/hr, e.g. around 375 kg/hr to around 500 kg/hr. Higher applications rates may also be used.
  • the rate of throughput can be increased by using higher steam application rates.
  • the moisture content of the DIET before and during treatment is between about 10% and about 23%.
  • moisture content refers to the percentage of oven volatiles present in the DIET material.
  • the moisture content of the DIET before and during treatment is between about 10% and 15.5%, optionally between about 10.5% and 15% or between about 11% and 14%.
  • the moisture content of the DIET may be about 10%, about 11%, about 12%, about 13%, about 14%, about 15%, about 16%, about 17%, about 18%, about 19%, about 20%, about 21%, about 22% or about 23%.
  • the moisture content of the DIET is between about 10% and 20%, optionally between about 10% and 18%, it is not necessary to redry the tobacco following the treatment process.
  • the DIET material is enclosed within, e.g. secured within, a moisture-retaining material, to limit moisture losses and to retain a desired level of moisture during the process.
  • the process may further comprise enclosing or securing the DIET material within the moisture-retaining material before treating the tobacco according to the process of the invention.
  • the DIET may be completely sealed within the moisture-retaining material. Alternatively, the DIET material may not be completely sealed within the moistureretaining material.
  • a moisture-retaining material is wrapped around the DIET material. In other embodiments, the moisture-retaining material is wrapped around a storage container which contains the DIET material. In some embodiments, the DIET material is placed within a moisture-retaining container.
  • the process of the invention may be carried out on DIET material, wherein the moisture-retaining material has been wrapped around the DIET material or wherein the moisture-retaining material has been wrapped around a storage container which contains the DIET material. In addition or alternatively, the process of the invention may be carried out on DIET material which has been placed in a moisture-retaining container.
  • the moisture-retaining material may be any material that is sufficiently impermeable to moisture to retain the desired amount of moisture during the treatment process.
  • the amount of moisture that is retained in the DIET material may be at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 91%, at least 92%, at least 93%, at least 94%, at least 95%, at least 96%, at least 97%, at least 98%, at least 99%, at least 99.5% or 100% of the moisture which was present in the DIET material prior to treatment. In some embodiments, between 99% and 100% of the moisture content of the DIET material is retained during the process.
  • the moisture-retaining material prefferably be resistant to degradation during the tobacco treatment process.
  • the temperature reached by the DIET material during the process may therefore be taken into consideration when selecting the moisture-retaining material.
  • the moisture-retaining material may comprise a flexible material. This flexible material may be wrapped around the DIET material and/or formed into a pouch into which the DIET is placed.
  • the moisture-retaining material comprises plastic material.
  • the moisture-retaining material comprises flexible polymeric material, optionally a polymeric or plastic film.
  • the moisture-retaining material comprises polyethylene.
  • the moisture-retaining material comprises polyesters, nylon and/or polypropylene.
  • the moisture-retaining material is Polyliner®. Polyliner® is available through a number of suppliers, including Plastrela Flexible Packaging, located in Brazil.
  • the moisture-retaining material may comprise a rigid material, such as metal for example, which is formed into a vessel or container.
  • a separate storage container as discussed below may not be required.
  • the moisture-retaining material may be pressure-resistant.
  • the process may comprise allowing the tobacco material to rest when enclosed within the moisture-retaining material for a rest period, before it is exposed to the ambient processing temperature.
  • the rest period may be at least 15 days, such as at least 30 days.
  • the rest period may be from 15-75 days such as 20-60 days or 30-45 days.
  • the DIET material has a packing density of 60 to 160 kg/m 3
  • the DIET material has a packing density at the start of the treatment of 70-140 kg/m 3 , 90-135 kg/m 3 , 100-130 kg/m 3 or 105-125 kg/m 3 .
  • the process/treatment starts when the DIET is exposed to the ambient processing temperature as defined herein. That is, the DIET has a packing density of 60 to 160 kg/m 3 , such as 70-140 kg/m 3 , 90-135 kg/m 3 , 100-130 kg/m 3 or 105-125 kg/m 3 , when the DIET is exposed to the ambient processing temperature.
  • Packing density herein is calculated by dividing the weight of the DIET by the volume occupied by the DIET.
  • the packing densities herein are to be calculated based on the total weight of the tobacco material, including any water/moisture in the tobacco material.
  • the packing density may be calculated by dividing the weight of tobacco placed in the storage container by the volume of the storage container.
  • the volume of the storage container and/or the volume enclosed by the moistureretaining material may be selected to achieve the desired packing density for the desired amount of tobacco to be treated, and at the same time allows the treatment of the tobacco to take place at a suitable rate.
  • the volume occupied by the DIET may be calculated by subtracting the volume of any empty space (e.g. any void space above the tobacco material after it has been placed within the moisture-retaining material and optionally the storage container) from the total volume enclosed by the moisture-retaining material.
  • any empty space e.g. any void space above the tobacco material after it has been placed within the moisture-retaining material and optionally the storage container
  • the packing density of the DIET material during and/or following treatment may be similar or substantially similar to the packing density of the DIET material at the start of the process. In some cases, the volume occupied by the DIET material decreases during the treatment and so the packing density of the DIET material is increased during and/or following the treatment.
  • the DIET material may be placed in a storage container after it has been enclosed or secured within a moisture-retaining material.
  • the DIET material may be placed in a storage container and then enclosed or secured within a moisture-retaining material, such as by wrapping a moisture-retaining material around the storage container. Placing the DIET in a container enables the tobacco to be handled easily.
  • the container may be oriented on its side. This arrangement may be particularly beneficial when the DIET material comprises tobacco lamina that is in a horizontal position when placed in the storage container, as placing the storage container on its side achieves a more even packing density.
  • the container has a volume of between about 0.2 m 3 and about 1.0 m 3 , optionally between about 0.4 m 3 and about 0.8 m 3 . In some embodiments, the container has a volume of about 0.7 m 3 .
  • the volume occupied by the DIET material at the start of the process is between about 0.2 m 3 and about 1.0 m 3 , optionally between about 0.4 m 3 and about 0.8 m 3 In some embodiments, the volume occupied by the DIET material at the start of the process is about 0.7 m 3 .
  • the storage container is a case for tobacco known as a C-48 box.
  • the C-48 box is generally made of cardboard and has dimensions of about 115 x 70 x 75 cm.
  • the DIET may be placed in a tobacco processing area.
  • tobacco processing area is the area, which can be a room or chamber, in which the treatment process is carried out.
  • the ambient process conditions i.e. the conditions of the tobacco processing area, may be controlled during the process. This may be achieved by placing the DIET material enclosed or secured within the moistureretaining material into a controlled environment, such as a chamber.
  • the DIET material may be placed on one or more rack(s) within a chamber, to allow optimal ventilation to maintain constant ambient process conditions around the tobacco.
  • the rack(s) may have one or more shelve(s) comprising bars with gaps between the bars and/or other apertures, to assist in the maintenance of constant ambient process conditions around the tobacco.
  • the ambient processing humidity may be maintained at a level to avoid significant moisture loss from the DIET material.
  • ambient processing humidity refers to the humidity of the tobacco processing area.
  • ambient relative processing humidity refers to the relative humidity of the tobacco processing area.
  • the ambient relative processing humidity is about 65%.
  • the ambient relative processing humidity may be at least 40%, at least 45%, at least 50%, at least 55%, at least 60%, at least 65% or at least 70%.
  • the ambient processing temperature is at least about 45°C. In some embodiments, the ambient processing temperature is at least about 50°C. In some embodiments, the ambient processing temperature may be maintained at above 55°C, optionally at about 60°C.
  • the term ‘ambient processing temperature’ refers to the temperature of the tobacco processing area.
  • the ambient processing temperature is at least 46°C, at least 47°C, at least 48°C, at least 49°C, at least 50°C, at least 51°C, at least 52°C, at least
  • the ambient processing temperature is up to 60°C, up to 70°C, up to 75°C, up to 80°C, up to 85°C, up to 90°C, up to 95°C, up to 100°C, up to 105°C, up to 110°C, up to 115°C or up to 120°C.
  • the ambient processing humidity may be about 30-70 g water/m 3 . In embodiments in which the ambient processing temperature is about 55°C, the ambient processing humidity may be about 40-80 g water/m 3 . In embodiments in which the ambient processing temperature is about 60°C, the ambient processing humidity may be about 50-110 g water/m 3 . In embodiments in which the ambient processing temperature is about 70°C, the ambient processing humidity may be about 50-160 g water/m 3 . In embodiments in which the ambient processing temperature is about 80°C, the ambient processing humidity may be about 50-230 g water/m 3 .
  • the ambient processing humidity may be about 50-340 g water/m 3 . In embodiments in which the ambient processing temperature is about 100°C or higher, the ambient processing humidity may be about 50-500 g water/m 3 .
  • the ambient processing temperature is 60°C and the ambient relative processing humidity is 60%.
  • the temperature of the DIET material reaches the ambient processing temperature.
  • the DIET material may reach the ambient processing temperature within a short period of time.
  • the DIET material may reach the ambient processing temperature within 4 to 10 days, optionally within 5 to 9 days, within 7 to 9 days and/or within 4 to 7 days.
  • the amount of DIET treated may be optimised for the heat to be transferred to the centre of the tobacco material sufficiently rapidly.
  • the rate at which the temperature of the DIET material rises and reaches the ambient processing temperature will be dependent upon a number of factors, including the ambient processing temperature, the density of the DIET and the overall amount of DIET being treated.
  • the DIET material reaches a temperature of above 55°C and/or at least 60°C within about 9 days. In some embodiments, the DIET material reaches a temperature of above 55°C and/or at least 60°C within about 7 days. In some embodiments, the DIET material reaches a temperature of above 55°C and/or at least 60°C within about 5 days. In such embodiments, the ambient processing temperature may be 60°C.
  • the temperature to which the DIET material is raised is at least about 55°C or at least about 60°C. Additionally or alternatively, the temperature to which the DIET material should be raised may be up to about 80°C, up to about 85°C, up to about 90°C, up to about 95°C, or up to about 100°C.
  • the beneficial effects of the processing according to the invention may be achieved within shorter processing periods by employing a higher ambient processing temperature.
  • the temperature of the DIET material may rise during the treatment process, to reach a second temperature that is higher than ambient processing temperature. This may be achieved with the assistance of exothermic reactions taking place during the treatment process.
  • the DIET material reaches a second temperature which is above the ambient processing temperature.
  • the second temperature is at least 1°C above the ambient processing temperature, at least 2°C, at least 3°C, at least 4°C, at least 5°C, at least 7°C, at least 10°C, at least 12°C, at least 15°C, at least 17°C or at least 20°C above the ambient processing temperature.
  • the DIET material reaches a second temperature which is above the ambient processing temperature within about 7 to 13 days, and/or the second is reached within about 13 days or within about 11 days.
  • the DIET material reaches a second temperature of at least 5°C above the ambient processing temperature within about 11 to 13 days.
  • the temperature of the DIET material may reach up to 60°C, up to 65°C, up to 70°C, up to 75°C, up to 80°C, up to 85°C, up to 90°C, up to 95°C, up to 100°C, up to 105°C, up to 110°C, up to 115°C, up to 120°C, up to 125°C, up to 130°C, up to 135°C, up to 140°C, up to 145°C or up to 150°C during the treatment process.
  • the temperature of the DIET material may reach at least 60°C, at least 65°C, at least 70°C, at least 75°C, at least 80°C, at least 85°C, at least 90°C, at least 95°C, at least 100°C, at least 105°C, at least 110°C, at least 115°C, at least 120°C, at least 125°C, at least 130°C, at least 135°C, at least 140°C, at least 145°C or at least 150°C during the treatment process.
  • the upper temperature may be limited by the thermal tolerance of the moisture-retaining material.
  • the temperature of the DIET material may reach between about 55°C and about 90°C, between about 55°C and about 80°C, or between 60°C and about 70°C.
  • the DIET may be enclosed or secured within the moisture-retaining material and exposed to the ambient processing temperature for a sufficiently long period of time for the DIET to develop the desirable organoleptic properties, and for a sufficiently short period of time to not cause unwanted delay in the tobacco supply chain.
  • the DIET material is enclosed or secured within the moisture-retaining material for a period of time and at an ambient processing temperature and ambient processing humidity suitable to give rise to an increase in the temperature of the tobacco to or above a threshold temperature, wherein the moisture content of the tobacco is between about 10% and 23%.
  • the threshold temperature is 55°C, 60°C or 65°C.
  • the DIET material is exposed to the ambient processing temperature of above 45°C (or any of the ambient processing temperatures disclosed herein) for about 5 to 65 days, such as 10 to 50 days, 20 to 45, 30 to 40 days or 35 to 40 days.
  • the duration of the treatment (excluding any period where the DIET material is enclosed or secured within the moisture-retaining material before being exposed to the ambient processing temperature) may be about 5 to 65 days, such as such as 10 to 50 days, 20 to 45 days, 30 to 40 days or 35 to 40 days.
  • the treatment duration may be 35 to 45 days.
  • the treatment duration may be 30-40 days.
  • the DIET material is exposed to the ambient processing temperature of above 45°C (or any of the ambient processing temperatures disclosed herein) for about 30 to 65 days, such as about 40 to 50 days, or about 43 to 48 days.
  • the duration of the treatment (excluding any period where the DIET material is enclosed or secured within the moisture-retaining material before being exposed to the ambient processing temperature) may be about 30 to 65 days, such as about 40 to 50 days, or about 43 to 48 days.
  • Increasing the duration of the treatment may increase the quantity of products of the Maillard reaction and may thereby provide a more intense flavour profile of the treated DIET.
  • Embodiments in which the DIET material reaches a higher temperature may require a shorter process period than embodiments in which the DIET material reaches a lower temperature.
  • the process involves treating the DIET material until the temperature of the DIET material reaches a target temperature, and then allowing the tobacco material to cool. This cooling may be effected by removing the DIET material from the processing area which is being held at an elevated temperature.
  • the target temperature is 60°C, 61°C, 62°C, 63°C, 64°C, 65°C, 66°C, 67°C, 68°C, 69°C or 70°C.
  • the target temperature is within the range of 62 to 67°C.
  • the target temperature may differ for different types of tobacco.
  • the DIET may be allowed to rest for a stabilisation period.
  • the DIET typically remains enclosed within, or secured within, the moisture-retaining material during this stabilisation period.
  • the stabilisation period may be initiated by removing the DIET material from the processing area which is being held at an elevated temperature.
  • the DIET material may be transported to a different processing area at a lower temperature, which may be about 30 °C or below (such as from about 18 °C to about 30 °C, or from about 20 °C to about 25 °C, e.g. around 22 °C).
  • the temperature of the DIET gradually reduces, typically to a temperature of about 30 °C or below (such as from about 18 °C to about 30 °C, or from about 20 °C to about 25 °C, e.g. around 22 °C).
  • the moisture content on the periphery (or on the outside or on the surface) of the body (such as a bale) of the dry ice expanded tobacco is typically higher than the moisture content in the centre (or core) of the body of the dry ice expanded tobacco.
  • moisture from the peripheral dry ice expanded tobacco may be absorbed back by the dry ice expanded tobacco in the centre/core.
  • the moisture is typically not homogeneously distributed throughout the batch of treated dry ice expanded tobacco, with the dry ice expanded tobacco on the periphery of the batch having a higher moisture content than the dry ice expanded tobacco at the centre (or core) of the batch.
  • the moisture may become homogeneously distributed throughout the batch of treated tobacco material. This may help to prevent microbial growth on the treated dry ice expanded tobacco at the periphery of the batch and thereby reduce waste and improve the shelf life of the treated dry ice expanded tobacco.
  • the moisture content of the DIET after the stabilisation period may be between about 10% and about 18%, optionally between about 10% and about 15.5%, optionally between about 10.5% and about 15%, such as between about 11% and about 14%.
  • the duration of the stabilisation period may be at least 15 days, such as at least 30 days.
  • the stabilisation period may be from 15-75 days, such as 20-60 days or 30-45 days.
  • the stabilisation period is around 40 days.
  • the stabilisation period may also enable the storage container to regain rigidity which is reduced during the treatment process. This may facilitate subsequent handling and transportation of the treated dry ice expanded tobacco material.
  • the inventors have discovered that the treatment process described herein may lead to the formation of hard clumps (which may also be referred to as blocks or pads) of DIET tobacco. Tobacco clumps may also form during the stabilisation period in which the temperature of the treated DIET gradually reduces. Such clumps may need to be removed before the treated DIET can be used in products such as combustible aerosol provision systems and/or components thereof. Moreover, the inventors have identified that such tobacco clumps do not form when treating other forms of tobacco to DIET, such as when treating lamina tobacco which has not previously been dry ice expanded. Without wishing to be bound by theory, the inventors believe that the tobacco clumps form due the compressible, or fluffy, nature of the dry ice expanded tobacco.
  • the dry ice expanded tobacco material at the top of the moisture retaining material may compress the dry ice expanded tobacco material beneath it, leading to the formation of compacted tobacco layers, or tobacco clumps, in the lower portion of the body, or batch, of dry ice expanded tobacco being treated.
  • the process further comprises one or more steps of breaking up any clumps of tobacco material formed during treatment of the DIET.
  • the process may further comprise applying one or more shear forces to clumps of tobacco material and/or shredding the tobacco clumps.
  • the process may also be done manually, e.g. by using hands or a hand-operated tool (e.g. hammer, mallet, pole, etc.) to break up the clumps of tobacco material formed during treatment of the DIET.
  • a hand-operated tool e.g. hammer, mallet, pole, etc.
  • the process may be carried out using machinery, for example as part of a production line.
  • the process may further comprise passing the treated DIET through one or more rollers to break up any tobacco clumps in the treated DIET.
  • each of the one or more rollers comprises a plurality of teeth, spikes and/or protruding rods on the surface thereof.
  • the one of more rollers may be one or more doffers.
  • the treated dry ice expanded tobacco is typically spread out over a conveying means, such as a conveyor belt, configured to transport the treated DIET towards the rollers.
  • the conveying means and one or more rollers may be arranged such that in use the treated dry ice expanded tobacco drops through, or falls through, the one or more rollers, thereby breaking up the one or more tobacco clumps.
  • a plurality of conveying means may be staggered such that there are one or more drops between them and one or more rollers may be arranged in the one or more drops.
  • the process may comprise multiple sequential rolling steps.
  • the one or more rolling steps are continued until the wt% of tobacco clumps reaches a target value, or until the wt% of tobacco material having a particle size of 2.5 cm or less reaches a target value.
  • the target value may be in any the ranges set out below, such as in the range of less than or equal to 15 wt% of tobacco clumps or the the range of 85 wt% or more of the DIET having a particle size of 2.5 cm or less.
  • the process may further comprise a first rolling step using one or more first rollers comprising a plurality of first teeth, first spikes and/or first protruding rods on the surface thereof and a second rolling step using one or more second rollers comprising a plurality of second teeth, second spikes and/or second protruding rods on the surface thereof, wherein the spacing between the plurality of first teeth, first spikes and/or first protruding rods is greater than the spacing between the plurality of second teeth, second spikes and/or second protruding rods. Any tobacco clumps are broken up into smaller clumps having a first particle size in the first rolling step.
  • the smaller tobacco clumps provided by the first rolling step are then broken up into yet smaller clumps having a smaller second particle size in the second rolling step.
  • the first rolling step occurs once and the second rolling step occurs two or more times. Performing the second rolling step multiple times may further reduce the wt% of tobacco clumps in the treated DIET.
  • the second rolling step occurs twice, that is the treated DIET is passed through the one or more second rollers twice.
  • the wt % of tobacco clumps refers to the mass percentage of the treated DIET material which does not pass through a mesh having a 2.5 cm x 2.5 cm hole size, relative to the total mass of the treated DIET material.
  • the one or more steps of breaking up any clumps of tobacco material provides DIET comprising less than or equal to 15 wt% (i.e. 0-15 wt%) of tobacco clumps, optionally less than or equal to 10 wt% of tobacco clumps, such as less than or equal to 5 wt% of tobacco clumps, less than or equal to 2 wt % of tobacco clumps, or less than or equal to 1 wt% of tobacco clumps.
  • the one or more steps of breaking up any clumps of tobacco material may provide DIET in which 85 wt% or more (i.e. 85-100 wt%) of the DIET has a particle size of 2.5 cm or less, optionally wherein 90 wt% or more, such as 95 wt% or more, 98 wt% or more, or 99 wt% or more of the DIET has a particle size of 2.5 cm or less.
  • the wt % of the treated DIET material having a particle size of 2.5 cm or less denotes the mass percentage of the treated DIET material which passes through a mesh having a 2.5 cm x 2.5 cm hole size, relative to the total mass of the treated DIET material.
  • the treated DIET may be more rapidly cooled and the stabilisation period described above can surprisingly be avoided without adversely affecting the fill value, moisture content, moisture distribution and taste profile of the treated DIET.
  • the temperature of the DIET may decrease to a temperature of about 30 °C or below (such as from about 18 °C to about 30 °C, or from about 20 °C to about 25 °C, e.g. around 22 °C) over a period of from 0.05 to 3 hours, optionally from 0.1 to 2 hours, such as from 0.15 to 1 hours or from 0.2 to 0.7 hours.
  • a further aspect of the invention is directed to a process comprising breaking up any tobacco clumps in a treated DIET material which has been produced by a process as described in the Summary.
  • the embodiments described above apply mutatis mutandis to this aspect of the invention.
  • Filling value (also referred to herein as fill value) is a measure of the volume occupied by a given mass of tobacco when a given pressure is applied at a given moisture content. That is, the fill value is a measure of the ability of a material to occupy a specific volume at a given moisture content. In this invention, filling value may be determined by Test Method A as disclosed in the Examples section below.
  • the high fill value of the dry ice expanded tobacco is maintained during the process.
  • the fill value of the dry ice expanded tobacco may even increase during the process.
  • the fill value of the treated DIET at 13.5% moisture content is at least 6 cm 3 /g, such as at least 6.5 cm 3 /g or at least 7 cm 3 /g.
  • the fill value of the treated DIET at 13.5% moisture content is 6 to 10 cm 3 /g, such as 6.5 to 9 cm 3 /g or 7 to 8 cm 3 /g.
  • the fill value of the untreated DIET at 13.5% moisture content is at least 6 cm 3 /g, such as at least 6.5 cm 3 /g or at least 7 cm 3 /g. In some embodiments, the fill value of the untreated DIET at 13.5% moisture content is 6 to 10 cm 3 /g, such as 6.5 to 9 cm 3 /g or 7 to 8 cm 3 /g.
  • the organoleptic properties of the tobacco material is a result of a reduction in the negative properties, for example as a result of a reduction in tobacco material components that have an unpleasant taste or have an irritant effect.
  • the organoleptic properties are changed by an increase in the positive properties, for example as a result of the increase in or introduction of components that make a positive contribution to the organoleptic properties, such as components having pleasant flavours.
  • the tobacco material is treated so that it has desirable organoleptic properties that are produced in a reliable way and at relatively high volumes.
  • the process is a batch process. After the DIET has been incubated for the desired length of time, the treated tobacco may be cooled down while remaining in the moisture-retaining material.
  • the process parameters are sufficiently gentle for the treated DIET material to maintain some or all of its physical properties.
  • the DIET material remains sufficiently intact following treatment to allow handling and/or processing for incorporation into a tobacco-containing product, such as a smoking article. This enables the treated DIET material to undergo handling in accordance with standard processes.
  • the treated DIET material may have a different colour from untreated DIET material.
  • the DIET material is darker than untreated tobacco material.
  • the treated DIET material has organoleptic properties that are acceptable and/or desirable for the consumer.
  • tobacco material with desirable organoleptic properties can be produced by the treatment of DIET under a specific set of conditions, and without requiring the addition of one or more further chemical(s), which may be hazardous and/or expensive.
  • the treated DIET does not need to undergo an additional treatment step to remove the further chemical(s), which would add extra cost and time to the tobacco treatment process.
  • the organoleptic properties of the treated DIET material may be developed when the tobacco material is enclosed or secured within the moisture-retaining material, during which period the components in the tobacco material undergo chemical changes and modifications, to give desirable organoleptic characteristics to the final product.
  • the treated tobacco material may, in some embodiments, have a sweet spicy and/or dark note.
  • the treated tobacco material may not, in some embodiments, have a dry and/or bitter note.
  • the chemical composition of the treated DIET material differs significantly from untreated DIET material.
  • the majority of the sugars in the treated DIET material are converted and the concentration of nicotine and total amino acids is reduced.
  • the change in the levels of at least some of these compounds is due at least in part to the Maillard reaction taking place during the process.
  • a caramelisation reaction may also be taking place during the process, which may lead to reduced levels of reducing and non-reducing sugars.
  • the process may therefore lead to an increase in at least one of the products of the Maillard reaction in the treated DIET material.
  • Products of the Maillard reaction include:
  • the treated DIET material may, in some embodiments, contain a reduced level of nicotine compared with untreated tobacco material, as shown in the Example. Nicotine is known to have a bitter taste and therefore having reduced levels of this compound can have a positive effect on the taste and flavour of the treated tobacco material.
  • DIET material with desirable organoleptic properties advantageously removes the requirement to add further substances to the tobacco to provide or enhance its organoleptic properties.
  • Such substances include flavourants and/or aromatising ingredients.
  • flavour and “flavourant” refer to materials which, where local regulations permit, may be used to create a desired taste or aroma in a product for adult consumers. They may include extracts (e.g., licorice, hydrangea, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, menthol, Japanese mint, aniseed, cinnamon, herb, Wintergreen, cherry, berry, peach, apple, Drambuie, bourbon, scotch, whiskey, spearmint, peppermint, lavender, cardamon, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, honey essence, rose oil, vanilla, lemon oil, orange oil, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, piment, ginger, anise, coriander, coffee, or a mint oil from any species of the genus Mentha),
  • extracts e.g.,
  • the treated DIET material may be incorporated into a combustible aerosol delivery system, which may also be referred to as a smoking article herein.
  • delivery system is intended to encompass systems that deliver at least one substance to a user, and includes combustible aerosol provision systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for roll-your- own or for make-your-own cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokable material).
  • combustible aerosol provision systems such as cigarettes, cigarillos, cigars, and tobacco for pipes or for roll-your- own or for make-your-own cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokable material).
  • a “combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is combusted or burned during use in order to facilitate delivery of at least one substance to a user.
  • the combustible aerosol provision system is selected from the group consisting of a cigarette, a cigarillo and a cigar.
  • the disclosure relates to a component for use in a combustible aerosol provision system, such as a filter, a filter rod, a filter segment, a tobacco rod, a spill, an aerosol-modifying agent release component such as a capsule, a thread, or a bead, or a paper such as a plug wrap, a tipping paper or a cigarette paper.
  • a component for use in a combustible aerosol provision system such as a filter, a filter rod, a filter segment, a tobacco rod, a spill, an aerosol-modifying agent release component such as a capsule, a thread, or a bead, or a paper such as a plug wrap, a tipping paper or a cigarette paper.
  • the treated DIET material may be used for roll-your-own tobacco and/or pipe tobacco.
  • the treated DIET material may be blended with one or more tobacco materials before being incorporated into a smoking article or used for roll-your-own or pipe tobacco.
  • tobacco extracts may be created from DIET material which has undergone the processing described herein.
  • the extract may be a liquid, for example it may be an aqueous extract.
  • the extract may be produced by supercritical fluid extraction.
  • one aspect provides a process for manufacturing a tobacco extract from DIET tobacco material which has been treated by the process described herein.
  • the extracts may be used in combustible aerosol provision systems.
  • the extracts may be added to tobacco or another material for combustion in a smoking article .
  • the favourable change in the organoleptic properties of the DIET tobacco means that the treated tobacco can be added to tobacco blends (for example for use in a smoking article), or to a combustible aerosol delivery system or to a component thereof, in higher quantities than untreated DIET tobacco without compromising the organoleptic properties of the tobacco blends, combustible aerosol delivery system or component thereof.
  • the processes described herein may further comprise incorporating the treated tobacco into a blend.
  • a tobacco blend may comprise the treated tobacco in an amount of from 1 to 60 wt%, such as from 5 to 60 wt%, from 10 to 55 wt%, from 15 to 50, or from 20 to 45 wt %, relative to the total weight of the blend.
  • the blend may further comprise one or more other tobacco varieties.
  • the one or more other tobacco varieties may include one or more Virginia tobaccos, one or more Burley tobaccos, one of more Oriental tobaccos and combinations thereof.
  • the treated dry ice expanded tobacco may contribute dark taste characteristics such that the blend can provided sufficient dark taste notes with lower inclusions of Burley tobacco varieties.
  • the aerosol-former material may comprise one or more constituents capable of forming an aerosol.
  • the aerosol-former material may comprise one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.
  • Smokable materials for use in combustible aerosol provision systems may typically comprise lower amounts of aerosol-former materials than aerosol-generating materials for use in non-combustible aerosol provision systems.
  • a smokable material comprising the DIET may comprise aerosol former in a total amount of from 0 to 20 wt% calculated on a dry weight basis (DWB), such as from 0.1 to 10 wt% (DWB), 0.25 to less than 10 wt% (DWB), such as 0.5 to 9 wt% (DWB) or 1 to 5 wt% (DWB).
  • DWB dry weight basis
  • the smokable material may comprise the aerosol former in an amount of less than 20 wt% (DWB), less than 10 wt% (DWB), less than 9 wt% (DWB) or less than 5 wt% (DWB).
  • dry weight basis refers to the whole of the smokable material, other than any water, and may include components which by themselves are liquid at room temperature and pressure, such as glycerol.
  • the DIET provided by the processes described herein, or a smokable material comprising the DIET (for example in combination with an aerosol-former material), may be blended with further components to provide a blend, for example as set out above.
  • the total amount of aerosol-former present in the blend may be from 0 to less than 4 wt% (DWB), such as 0.1 to 2 wt%.
  • DWB dry weight basis
  • DWB refers to the whole of the blend, other than any water, and may include components which by themselves are liquid at room temperature and pressure, such as glycerol.
  • the fill value of the tobacco was measured according to the following process.
  • a 15 g sample of the tobacco material was deposited into a 60 mm diameter cylinder of a densimeter and then the tobacco material was compressed with a 2.90 ⁇ 0.03 kg piston for 30 seconds. The height of the piston in the densimeter as well as the moisture content of the samples were measured. The fill values of the samples were calculated according to the following formulae.
  • the fill value was then determined using the measured volume and mass of tobacco material according to Formula 2:
  • the fill value was corrected to account for its moisture content using Formula 3:
  • Moisture content is measured as the reduction in mass when a sample is dried in a forced draft oven at a temperature regulated to 110°C ⁇ 1°C for three hours ⁇ 0.5 minutes. After drying, the sample is cooled in a desiccator to room temperature for approximately 30 minutes, to allow the sample to cool.
  • Lamina Virginia and Burley tobacco were conditioned, mixed, cut and dried.
  • the tobacco material was then formed into dry ice expanded tobacco.
  • the cut Virginia and cut Burley tobacco were wetted.
  • the Virginia and Burley tobacco were then blended.
  • the wet and optionally blended tobacco material had a moisture content of around 26%.
  • the tobacco material was then fed into an impregnator vessel, which was subsequently charged with carbon dioxide at a temperature of -20 °C for around 6 minutes under pressure.
  • the impregnated tobacco material was fed into a sublimator and the pressure was then reduced to allow the liquid carbon dioxide to solidify.
  • the impregnated tobacco material was then heated in a gas stream at a temperature of 330 °C which led to rapid volatilisation of the moisture and carbon dioxide in the tobacco material.
  • Sample A below is dry ice expanded of lamina Virginia tobacco.
  • Sample R below is a 1:1 w/w blend of dry ice expanded lamina Virginia and Burley tobacco.
  • Tobacco stems obtained by green-leaf threshing were wet to a moisture content of 25- 35% and then cut to a cut width of 25-28 CPI.
  • the cut stem was then expanded by steam treatment involving heating to a temperature of 180-250 °C for a period of 15 seconds to 3 minutes, leading to vaporisation of water within the tobacco cells and expansion of the tobacco. After the steam treatment the stem tobacco had a moisture content of 13-14%.
  • 80 kg of the DIET tobacco was packed in a single walled cardboard box having external dimensions of 0.835 m x 1.120 m x 0.765 m, wrapped with polyethylene liner (Polyliner®), and was set to rest for a minimum period of 30 days before being exposed to the ambient processing conditions of 60°C and 60% relative humidity and a process time of 35, 37 or 39 days (for Sample A) or 35 days (for Sample R).
  • the packing density of the tobacco before treatment was about 123 kg/m 3 .
  • 70 kg of the expanded stem was packed in a C-48 box, wrapped with polyethylene liner (Polyliner®), and was set to rest for a minimum period of 30 days before being exposed to the ambient processing conditions of 60°C and 60% relative humidity and a process time of 14, 21 or 28 days.
  • Polyliner® polyethylene liner
  • Cigarettes comprising the untreated DIET, untreated expanded stem, treated DIET, or treated expanded stem were produced. A blind smoking trial was then conducted by expert smokers. No significant difference in taste was observed for the treated expanded stem as compared to the untreated expanded stem. However, an increase in spicy taste notes was observed for the treated DIET (for both Sample A and Sample R) as compared to the untreated DIET. An increase in tannin taste notes was also observed for the treated Sample R DIET compared to the untreated control. Thus, the taste properties of DIET tobacco were unexpectedly improved by the treatment, unlike other forms of expanded tobacco (expanded stem).
  • Table 1 Fill value of treated and untreated DIET tobacco
  • the nicotine content of the treated tobacco was analysed by a colorimetric method (continuous flow analysis using an AutoAnalyzer 3 machine). The results of the analysis are provided in Table 2.
  • the tobacco material contains a reduced amount of nicotine after treatment compared with before treatment.
  • the total sugar content of the treated tobacco was analysed by a colorimetric determination of all reducing substances plus sucrose.
  • the colorimetric method was continuous flow analysis using an AutoAnalyzer 3 machine. The results of the analysis are provided in Table 3.
  • Lamina Virginia tobacco was treated by the method set out in Example 1 for Sample A for a duration of 39 days. After the treatment, the temperature of the DIET tobacco was 64 °C. The temperature of the tobacco was then gradually reduced to 22 °C during a stabilisation period of 40 days. Large clumps of tobacco were observed within the treated DIET material.
  • the properties of the tobacco after the stabilisation period are shown in the table below (Test 1). After the stabilisation period, the DIET tobacco had a moisture content (OV) of 14% and a fill value of 6.8 cc/g. The proportion of the tobacco which did not pass through a mesh having a hole size of 2.5 cm x 2.5 cm was 40 wt%.
  • Test 2 immediately after the treatment, the tobacco material was conveyed through a first set of doffers in the form of rollers comprising a plurality of rods protruding from the surface thereof, and then through a second set of doffers in the form of a roller comprising a plurality of rods protruding from the surface thereof.
  • the spacing between the protruding rods on the first set of doffers was greater than the spacing between the protruding rods on the second set of doffers.
  • Test 3 the tobacco material was conveyed for a second time through the second set of doffers.
  • Test 4 the tobacco material was conveyed for a third time through the second set of doffers.
  • the cooling time for Tests 2-4 was 30 minutes or less.
  • Figure 4 shows treated DIET being passed through a set of doffers. having a hole size of 2.5 cm x 2.5 cm
  • Cigarettes comprising the untreated DIET, untreated expanded stem, treated DIET, or treated expanded stem were produced.
  • a blind smoking trial was then conducted by expert smokers.
  • a panel of expert smokers determined that there was no significant difference between the sensorial profile of the cigarette comprising the tobacco produced in Test 2, Test 3 and Test 4 vs the control sample (a cigarette comprising the tobacco produced in Test 1).

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Manufacture Of Tobacco Products (AREA)

Abstract

L'invention propose un processus de production de tabac expansé à glace sèche et du tabac expansé à glace sèche traité pouvant être obtenu par ce processus. L'invention propose également un système de fourniture d'aérosol combustible, ou un article ou un composant associé, comprenant le tabac expansé à glace sèche traité.
PCT/EP2024/050880 2023-01-16 2024-01-16 Traitement de tabac WO2024153624A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB2300613.3 2023-01-16
GBGB2300613.3A GB202300613D0 (en) 2023-01-16 2023-01-16 Tobacco treatment

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WO2024153624A1 true WO2024153624A1 (fr) 2024-07-25

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3982550A (en) * 1975-06-05 1976-09-28 Philip Morris Incorporated Process for expanding tobacco
EP2394520A1 (fr) * 2009-02-07 2011-12-14 Kazuhiko Shimizu Gabarit de fumage sans combustion
WO2012104621A1 (fr) * 2011-02-01 2012-08-09 British American Tobacco (Investments) Limited Article à fumer
GB2521737A (en) * 2013-10-31 2015-07-01 British American Tobacco Co Tobacco treatment

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3982550A (en) * 1975-06-05 1976-09-28 Philip Morris Incorporated Process for expanding tobacco
EP2394520A1 (fr) * 2009-02-07 2011-12-14 Kazuhiko Shimizu Gabarit de fumage sans combustion
WO2012104621A1 (fr) * 2011-02-01 2012-08-09 British American Tobacco (Investments) Limited Article à fumer
GB2521737A (en) * 2013-10-31 2015-07-01 British American Tobacco Co Tobacco treatment

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