CA1246418A - Process for manufacturing reconstituted tobacco - Google Patents
Process for manufacturing reconstituted tobaccoInfo
- Publication number
- CA1246418A CA1246418A CA000481819A CA481819A CA1246418A CA 1246418 A CA1246418 A CA 1246418A CA 000481819 A CA000481819 A CA 000481819A CA 481819 A CA481819 A CA 481819A CA 1246418 A CA1246418 A CA 1246418A
- Authority
- CA
- Canada
- Prior art keywords
- tobacco
- stem
- fibrous
- mixture
- lamina
- Prior art date
- Legal status (The legal status 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 status listed.)
- Expired
Links
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
Landscapes
- Manufacture Of Tobacco Products (AREA)
Abstract
UNITED STATES PATENT APPLICATION
FOR
PROCESS FOR MANUFACTURING RECONSTITUTED TOBACCO
BY
DAVID G. STRUBEL
AND
ROBERT A. SANFORD
ABSTRACT
A process for manufacturing reconstituted tobacco from tobacco stems and tobacco fines includes treating the tobacco stems to a fibrous form, and mixing the fibrous tobacco stems with tobacco lamina fines. The mixture is then deposited on a moving mesh screen whereon it is formed into a felt-like mat or sheet of generally uniform thickness. The reconstituted tobacco sheet is then removed from the mesh screen for further processing to produce a tobacco smoking article.
FOR
PROCESS FOR MANUFACTURING RECONSTITUTED TOBACCO
BY
DAVID G. STRUBEL
AND
ROBERT A. SANFORD
ABSTRACT
A process for manufacturing reconstituted tobacco from tobacco stems and tobacco fines includes treating the tobacco stems to a fibrous form, and mixing the fibrous tobacco stems with tobacco lamina fines. The mixture is then deposited on a moving mesh screen whereon it is formed into a felt-like mat or sheet of generally uniform thickness. The reconstituted tobacco sheet is then removed from the mesh screen for further processing to produce a tobacco smoking article.
Description
~Z~64~
li ¦¦ BACKEROUND OF THE INVENTION
1. Field of tbe Invention I T~is invention relates generally to a method of Il producing a reconstituted tonacco. More particularly, this ¦ invention relates to a method of manufacturing reconstituted tobacco whic~ is simpler, requires less energy and minimizes t~e treatment on toDacco, thus, preserving t~e natural flavor and taste c~aracteristics of the tobacco materials used to make reconstituted toDacco.
li ¦¦ BACKEROUND OF THE INVENTION
1. Field of tbe Invention I T~is invention relates generally to a method of Il producing a reconstituted tonacco. More particularly, this ¦ invention relates to a method of manufacturing reconstituted tobacco whic~ is simpler, requires less energy and minimizes t~e treatment on toDacco, thus, preserving t~e natural flavor and taste c~aracteristics of the tobacco materials used to make reconstituted toDacco.
2. Discussion of t~e Prior Art Duriny t~e manufacture of tobacco products such as cigarettes, cigars, pipe toDacco, a portion of t~e toaacco is oroken up and therefore too small to be used in the tobacco product. The stems and veins are also by-products removed from the toDacco leaves purchased from the grower. It has been the general practice of toDacco pro~uct manufacturers to process t~e fines and stems, ana mixtures thereof, into reconstituted toDacco w~icn is producea generally in a sheet-like form. T~e reconstitute~ tooacco is mixed with t~e toDacco and t~ereafter cut and incorporated into t~e tobacco products.
Tbe manufacture of reconstituted tobacco ~as oeen practiced for many years. Most commercial processers involved in the manufacturer of reconstituted tobacco include a series of steps whic~ consist of mixing the toDacco materials with water and grinding t~e materials to a smaller particle size to form a slurry. The slurry is then cast on an endless Dand and ~eated to remove the water. Binder material, suc~ as Guar Gum, Met~ylcellulose, or Sodium CarDoxymet~ylcellulose, is added to t~e slurry to assist in ~orming a coherent sheet. Furt~er, it ,, 6~
is known to use tbe so called "~aper" process ~here the tobacco is extracted and the tobacco fibers are processed on conventional paper equipment and t~e fibers are formed into a sheet on conventional paper machines. The tobacco extract is concentrate~ and added ~ack to the "paper" using a conventional sizing process. The sized reconstituted tobacco is then dried to remove excess water.
These conventional processes for manufacturing reconstituted tobacco treat the fine tobacco harshly. These treatments tenû to change the flavor characteristics of the starting tobacco and depending on the temperature used in drying, drive o~f or change the natural tobacco characteristics.
These conventional processes for producing reconstituted tobacco also require large amounts of energy to remove the water used as the ve~icle to cast the slurry in the form of steam energy. The present invention is a simpler process and should require less manpower to produce a reconstituted sheet material that heretofore known processes.
DESCRIPTION OF THE DRAWINGS
The invention will become even more clear upon reference to the accompanying drawings w~erein like numerals refer to like parts throughout and in which:
FIGURE 1 is a schematic representation of a system for carrying out the process of the present invention;
FIGURE 2 is a schematic representation of anot~er advantageous embodiment of a stage of the system of Figure l;
FIGURE 3 is a schematic representation of a further advantageous embodiment of a stage of the system of Figure l;
and,
Tbe manufacture of reconstituted tobacco ~as oeen practiced for many years. Most commercial processers involved in the manufacturer of reconstituted tobacco include a series of steps whic~ consist of mixing the toDacco materials with water and grinding t~e materials to a smaller particle size to form a slurry. The slurry is then cast on an endless Dand and ~eated to remove the water. Binder material, suc~ as Guar Gum, Met~ylcellulose, or Sodium CarDoxymet~ylcellulose, is added to t~e slurry to assist in ~orming a coherent sheet. Furt~er, it ,, 6~
is known to use tbe so called "~aper" process ~here the tobacco is extracted and the tobacco fibers are processed on conventional paper equipment and t~e fibers are formed into a sheet on conventional paper machines. The tobacco extract is concentrate~ and added ~ack to the "paper" using a conventional sizing process. The sized reconstituted tobacco is then dried to remove excess water.
These conventional processes for manufacturing reconstituted tobacco treat the fine tobacco harshly. These treatments tenû to change the flavor characteristics of the starting tobacco and depending on the temperature used in drying, drive o~f or change the natural tobacco characteristics.
These conventional processes for producing reconstituted tobacco also require large amounts of energy to remove the water used as the ve~icle to cast the slurry in the form of steam energy. The present invention is a simpler process and should require less manpower to produce a reconstituted sheet material that heretofore known processes.
DESCRIPTION OF THE DRAWINGS
The invention will become even more clear upon reference to the accompanying drawings w~erein like numerals refer to like parts throughout and in which:
FIGURE 1 is a schematic representation of a system for carrying out the process of the present invention;
FIGURE 2 is a schematic representation of anot~er advantageous embodiment of a stage of the system of Figure l;
FIGURE 3 is a schematic representation of a further advantageous embodiment of a stage of the system of Figure l;
and,
-3-I1 ~2~ 4~
FIGURE 4 is a schematic representation of yet another i advantageous em~odiment of a stage o~ t~e system of Figure 1.
DETAILED DESCRIPTION
I Figure 1 illustrates, in sc~ematic Format, a system, ¦¦ generally denoted as the numeral 10, for carrying out t~e process of the present invention for manufacturing reconstituted tobacco.
;~ T~e system 10 comprises a fibrillation stage 12, a mixing stage 14, and a reconstituted to~acco s~eet forming stage 16.
To~acco stems are fed from a source of tobacco stems 18 to the fibrillation stage 12 wherein t~e particle size of the stems is reduced to a size suitable for use in a smoking article. T~e fibrillation stage 12 can include, for example, a ~ammer mill or a disc refiner.
ToDacco fines are fed from a source of toDacco fines 20 to t~e mixing stage 14, and the fibrillated stems are fed from t~e fiDrillation stage 12 to t~e mixing stage 14. Tne to~acco fines and fiDrillated tobacco stems are thorougbly mixed toget~er in t~e mixing stage 12 to form a ~omogeneous mixture. The mixing stage 12 should be capaDle of not only mixing the fines and stems together, ~ut also prevent clumping of t~e mixture~ Toward this end, an air mixing device has been i~ found to oe aavantageous for tbe mixing stage 12. Tbe air ,I mixing device utilizes an air stream to tumble and, tbereGy mix i t~e to~acco fines and fibrillated stems, and break-up clumps of material.
¦ Tbe homogenous mixture of fines and fibrillated stems ¦ are then transferred to t~e sheet forming stage 16 for forming a mat of t~e mixture. As snown, t~e sheet forming stage 12 1~641~
comprises a reticulated endless belt conveyor 22. The mixture of fines ana fi~rillated stems are fed to a preselected area on the top flig~t of the helt conveyor 22 in an air stream passing througb a duct 24 communicating at one end with the mixing stage 14 and at the other end with the preselected area on t~e top flight of the belt conveyer 22. An air moving means 26, such as a ~lower, can oe associated ~ith the air duct 24 to generate t~e air stream through the duct 24 from the mixing stage 12 to the preselected area of t~e top flight of the belt conveyor 22. An air plenum cbam~er 28 is located beneath and open to the top flight of the belt conveyor 22 at the preselected area. A suction fan 30 is operatively associated with the plenum chamber 28 to create an air flow do~nwardly through the preselected area of the belt conveyor top flight into the plenum cbamber 28 as in~icated by the flow arro~s "A". Preferraoly, the air duct 24 directs the mixture of fines and fibrillated stems generally downwardly onto the preselected area of the Delt conveyor top flight. As the mixture is deposited on the preselected area of the moving conveyor Delt top flight, the air flow moving downwardly through the preselected area proauces a relatively even distribution of the tooacco mixture, thus9 forming a tobacco s~eet 32 of generally uniform thic~ness on the ~elt conveyor top flight.
The tooacco sheet forming stage 16 can also include tobacco binder application means 34, such as spray nozzles, for directing a to~acco ~inder material onto the tobacco sheet 32 moving from t~e preselected area of the belt conveyor top flig~t. Further, drying means 36 is provided downstream, relative to the direction of travel of the belt conveyor top flight, of the Dir~der application means }4 to aid in the rapid drying of t~ binder in the to~acco sheet 32 moving with the il ~1 ~I belt conveyor top flig~t. As illustrated, t~e drying means 36 !¦ includes a ~ood 38 located over the belt conveyor top flight by a distance adequate to allow the tobacco sheet 32 to pass il t~ereDeneat~. An air flow, indicated by flow arrows ~a~, upwaraly through t~e tobacco sheet 32 and into the hood 38 can ¦ be created oy air mo~ing means 40, suc~ as a fan, in 1 association wit~ t~e hood 38.
¦ With reference to Figure 2, it is contemplated t~at the binder material can be added to t~e tobacco fines and fiorillated tobacco stems oeing mixed in the mixing stage 14.
T~is can be accomplis~ed oy supplying the binder from a source of binder 134, thus, eliminating the binder application means 34 at tne belt conveyor 22.
As an additional option feature of tlle apparatus 10, calender rolls 42 can be provided along t~e path of t~e tobacco ~ s~eet 32 to further compress t~e tobacco sheet 32 to furt~er I reduce its tnickness.
Figure 3 illustrates a somewhat modified arrangement of t~e fiorillation stage 12 and mixing stage 14 of t~e apparatus 10. It is contemplated, as s~own, t~at tooacco stems and tobacco fines can oot~ be fed to t~e fibrillation stage 12 w~ic~ would function not only to fibrillate the tooacco stems, but also function as a pre-mixer of t~e stems and fines. T~e premixture of fibrillated stems and fines would t~en oe i conveyed to t~e mixing stage 14 for more thorough mixing an~
for oreaking up any clumps w~ich may ~ave formea in the mixture.
Il Figure 4 illustrates another modification of the Il apparatus lû. In this embodiment, t~e tobacco fines are fed ` from t~e source of fines 20 to a treatment station 44. In t~e treatment station 44, t~e tooacco fines are treated to release pectine material w~ic~ will function as a tobacco mixture !l I
Il ~6- ~
I
binder. Toward this end, the tobacco fines can be mixed with diammonium p~osp~ate, or pectic enzymes in the treating station 44. Tbe treated tobacco fines are t~en transferred to a pulping station 46 ~erein the treated fines are shredded. The s~redded, treated tobacco fines are t~en fed from the pulping station 46 to t~e mixiny stage 14 wherein it is thoroug~ly mixed wit~ the fiorillated to~acco stems from the fibrillation stage 12 to form a ~omogenous mixture to oe supplied to the tobacco sheet forming stage 16 for processing as hereina~ove discussea.
It is further contemplated that non-tobacco exten~ers suc~ as cellulose fiber and inorganic materials sucb as alumina will oe addea to t~e reconstituted toDacco in order to: 1) increase tbe volume of the reconstituted tobacco s~eet without t~e need of using more tobacco components, ana 2) modify the comDustibility of the reconstituted tobacco sheet. T~e non-tobacco extenders can ~e incorporated into tbe to~acco components at virtually any step in the process. For example, t~e non-to~acco extenders can oe added to t~e tobacco stems in the fi~rillation stage 12, at t~e mixing stage 14 or at the sheet forming stage 16.
A wide variety of material or synthetic binaers are suitaDle for use in t~e present invention provided that they are not inimical to t~e flavor of tbe tobacco. Specific examples of such suitable Dinders include natural vegeta~le gums suc~ as, for example, gum arabic, gum tragacanth, guar gum, locust bean gum, etc. Other suitable gums include carbo~ydrate gums from animal sources, such as glycogen, deaceteylated c~itin and t~e like, marine plant gums suc~ as algins, carageenans, and agar.
Il ~2~
Preferred binders which are particularly advantageous in the met~od of tbe present invention include treated cellulosic gums, such as cellulose et~ers, cellulose esters, and mixtures t~ereof. Specific examples of such binders include met~yl cellulose, ethyl cellulose, hydroxypropyl cellulose, methylhydroxyethyl cellulose, ethylbydroxyethyl cellulose, cellulose acetate, hydroxyethyl cellulose, so~ium carboxymethyl cellulose, etc.
Specific examples of forming smoking tooacco material according to the process of the present invention are as follows:
A 5û/5û mixture of flue-cured tooacco and ourley tooacco stems having approximately 12 percent moisture content by weig~t were passed throug~ a double disc refiner to produce a shredde~ product of hig~ly fiorillated fioers. Twenty grams of tbis mixture was mixed with thirty grams of cigarette tooacco waste fines ~aving a 12 percent moisture content oy weight, five grams of flue-cured lamina fines of -14 mesh and ~aving a 12 percent moisture content, and five grams of burley lamina fines of -14 mesh and having a 12 percent moisture content. T~e tooacco fines and the fibrillated tobacco stem mixture were tumbled together to evenly distribute the fiorillate~ stems throug~out the mixture ar,d to separate tbe intertwinea bundles or clumps of stem fibers to form a homogenous mixture. The homogenous mixture was conveyed in an air stream to, and impacted on, a 170 U.S. mesh screen under which a vacuum of 21 inches of Hg. was applied. T~e homogenous mixture was thereby evenly distriouted on the screen to a t~ickness of approximately 20 mils to form a sheet or mat of interlaced fibrillated stem fibers and toDacco fines. Twenty ll !
~1 ml of a 5 percent solution of NaCMC Grade 7LF sold ~y Hercules ! Chemical Co. was then sprayed on the sheet as a oinder. The sheet was next dried in a forced draft oven at 100C. After the sheet of reconstituted to~acco was dried, it was mixed ~ith regular strip tooacco an~ cut and formed into cigarettes.
¦ A reconstituted tonacco sheet is prepared on a mesh screen as in Example 1. The tobacco sheet is removed from the screen and passed through a pair of calender rolls to reduce the sheet thickness from 20 mils to 10 mils. From the calender rolls, the tooacco sheet of reduced thickness is dried in a forced draft oven at lû0C. The driea sheet of reconstituted tooacco is then mixea with tooacco stems, cut, ana formea into a cigarette.
Fifty grams of Pectic enzyme is dissolved in 300 grams of water. This solution is sprayed on 500 grams of flue-cured stems to raise the total moisture content of t~e stems to aoout 60 percent oy weig~. The enzyme treated stems are then maintained at aoout 25C for from 24 to 48 hours to allow the pectic enzyme to oreak down the pectin contained in the stems.
The pectins are the "glue" wbich hold the fioers of the stems together. After the stems are treated for a sufficient lengtb of time to break down and loosen the fibers, the stems are passed through a double disc refiner to proauce fiorillated, !l individual fioers. Next, 100 grams of the flue-cured lamina fines are added to the 50n grams of fiorillatea treatea stems, and mixed together to uniformly distrioute fibrillated stems and lamina fines and form a bomogenous mixture. This homogenous mixture is then conveyed in an air stream to, and impacted on a mesb screen wbich has a vacuum chamber Il, Il Il _g_ Il ~ 6~
therebeneath. The vacuum created by tne vacuum chamber beneath t~e homogenous mixture, and the force of impact of t~e tobacco mixture as it is ~lown on the screen cause the homogeneous mixture to form into a felt-like sheet or mat of intertwined fi~rillatea tobacco-stems with toDacco fines uniformly dispersed t~erethrough. T~e pectines liberated by t~e action of t~e pectic enzymes on t~e toDacco stems functioned as a "glue" to ~ond t~e intertwined, fibrillated tobacco stems and tobacco fines toge~her and form a reconstituted tonacco leaf on the s~eet. T~e sheet of reconstituted to~acco s~eet is removed from t~e mes~ screen and suDjected to ~eated air at 100C for a sufficient time to reduce t~e moisture content to a~out 12 percent ~y weight. T~e reconstituted toDaCco sheet is then passed t~rough cutters to produce discreet particles ~hich are added to cut leaf tobacco and formed into a cigarette.
A mixture of tobacco stem fibers and to~acco is prepareû as in Example 1. To this mixture is added 20 gms. of cellulose fioers prepared in a similar manner as tobacco stems.
The resulting blend of tobacco and cellulose is then tumbled together to distri~ute t~e cellulose fi~ers uniformly.
The mixture was t~en formed to a reconstituted to~acco in the same manner as in Example 1.
A portion of the mixture as per Example 4 is mixe~
wit~ an additional 20 gms. alumina tri-~ydrate (A1203.3H20) and that mixture is formed into an extended to~acco as per Example 1.
A reconstituted tooacco is prepared and formed as per Example 1. After the ~inder has oeen added, calcium car~onate 12~
.1 .
(CaC03) is dusted on top. The sheet is then dried and removed from the wire as per Example 1.
A reconstituted tobacco mat is formed on a wire as per Example 1 but at only 1/2 the thickness. After the Dinder has been a~ded, a second mixture prepared as per Example 5 is Dlown on top in a similar manner as per Example 1 to form a laminated s~eet. The laminated sheet is then dried and removed from the wire as per Example 1.
The foregoing detailed description is given primarily for clearness of understanding and no unnecessary limitations are to De understood therefrom for modifications will oecome oDvious to those skilled in t~e art upon reading this disclosure and may De made without departing from the spirit of the invention and scope of the appended claims.
11 , ""-
FIGURE 4 is a schematic representation of yet another i advantageous em~odiment of a stage o~ t~e system of Figure 1.
DETAILED DESCRIPTION
I Figure 1 illustrates, in sc~ematic Format, a system, ¦¦ generally denoted as the numeral 10, for carrying out t~e process of the present invention for manufacturing reconstituted tobacco.
;~ T~e system 10 comprises a fibrillation stage 12, a mixing stage 14, and a reconstituted to~acco s~eet forming stage 16.
To~acco stems are fed from a source of tobacco stems 18 to the fibrillation stage 12 wherein t~e particle size of the stems is reduced to a size suitable for use in a smoking article. T~e fibrillation stage 12 can include, for example, a ~ammer mill or a disc refiner.
ToDacco fines are fed from a source of toDacco fines 20 to t~e mixing stage 14, and the fibrillated stems are fed from t~e fiDrillation stage 12 to t~e mixing stage 14. Tne to~acco fines and fiDrillated tobacco stems are thorougbly mixed toget~er in t~e mixing stage 12 to form a ~omogeneous mixture. The mixing stage 12 should be capaDle of not only mixing the fines and stems together, ~ut also prevent clumping of t~e mixture~ Toward this end, an air mixing device has been i~ found to oe aavantageous for tbe mixing stage 12. Tbe air ,I mixing device utilizes an air stream to tumble and, tbereGy mix i t~e to~acco fines and fibrillated stems, and break-up clumps of material.
¦ Tbe homogenous mixture of fines and fibrillated stems ¦ are then transferred to t~e sheet forming stage 16 for forming a mat of t~e mixture. As snown, t~e sheet forming stage 12 1~641~
comprises a reticulated endless belt conveyor 22. The mixture of fines ana fi~rillated stems are fed to a preselected area on the top flig~t of the helt conveyor 22 in an air stream passing througb a duct 24 communicating at one end with the mixing stage 14 and at the other end with the preselected area on t~e top flight of the belt conveyer 22. An air moving means 26, such as a ~lower, can oe associated ~ith the air duct 24 to generate t~e air stream through the duct 24 from the mixing stage 12 to the preselected area of t~e top flight of the belt conveyor 22. An air plenum cbam~er 28 is located beneath and open to the top flight of the belt conveyor 22 at the preselected area. A suction fan 30 is operatively associated with the plenum chamber 28 to create an air flow do~nwardly through the preselected area of the belt conveyor top flight into the plenum cbamber 28 as in~icated by the flow arro~s "A". Preferraoly, the air duct 24 directs the mixture of fines and fibrillated stems generally downwardly onto the preselected area of the Delt conveyor top flight. As the mixture is deposited on the preselected area of the moving conveyor Delt top flight, the air flow moving downwardly through the preselected area proauces a relatively even distribution of the tooacco mixture, thus9 forming a tobacco s~eet 32 of generally uniform thic~ness on the ~elt conveyor top flight.
The tooacco sheet forming stage 16 can also include tobacco binder application means 34, such as spray nozzles, for directing a to~acco ~inder material onto the tobacco sheet 32 moving from t~e preselected area of the belt conveyor top flig~t. Further, drying means 36 is provided downstream, relative to the direction of travel of the belt conveyor top flight, of the Dir~der application means }4 to aid in the rapid drying of t~ binder in the to~acco sheet 32 moving with the il ~1 ~I belt conveyor top flig~t. As illustrated, t~e drying means 36 !¦ includes a ~ood 38 located over the belt conveyor top flight by a distance adequate to allow the tobacco sheet 32 to pass il t~ereDeneat~. An air flow, indicated by flow arrows ~a~, upwaraly through t~e tobacco sheet 32 and into the hood 38 can ¦ be created oy air mo~ing means 40, suc~ as a fan, in 1 association wit~ t~e hood 38.
¦ With reference to Figure 2, it is contemplated t~at the binder material can be added to t~e tobacco fines and fiorillated tobacco stems oeing mixed in the mixing stage 14.
T~is can be accomplis~ed oy supplying the binder from a source of binder 134, thus, eliminating the binder application means 34 at tne belt conveyor 22.
As an additional option feature of tlle apparatus 10, calender rolls 42 can be provided along t~e path of t~e tobacco ~ s~eet 32 to further compress t~e tobacco sheet 32 to furt~er I reduce its tnickness.
Figure 3 illustrates a somewhat modified arrangement of t~e fiorillation stage 12 and mixing stage 14 of t~e apparatus 10. It is contemplated, as s~own, t~at tooacco stems and tobacco fines can oot~ be fed to t~e fibrillation stage 12 w~ic~ would function not only to fibrillate the tooacco stems, but also function as a pre-mixer of t~e stems and fines. T~e premixture of fibrillated stems and fines would t~en oe i conveyed to t~e mixing stage 14 for more thorough mixing an~
for oreaking up any clumps w~ich may ~ave formea in the mixture.
Il Figure 4 illustrates another modification of the Il apparatus lû. In this embodiment, t~e tobacco fines are fed ` from t~e source of fines 20 to a treatment station 44. In t~e treatment station 44, t~e tooacco fines are treated to release pectine material w~ic~ will function as a tobacco mixture !l I
Il ~6- ~
I
binder. Toward this end, the tobacco fines can be mixed with diammonium p~osp~ate, or pectic enzymes in the treating station 44. Tbe treated tobacco fines are t~en transferred to a pulping station 46 ~erein the treated fines are shredded. The s~redded, treated tobacco fines are t~en fed from the pulping station 46 to t~e mixiny stage 14 wherein it is thoroug~ly mixed wit~ the fiorillated to~acco stems from the fibrillation stage 12 to form a ~omogenous mixture to oe supplied to the tobacco sheet forming stage 16 for processing as hereina~ove discussea.
It is further contemplated that non-tobacco exten~ers suc~ as cellulose fiber and inorganic materials sucb as alumina will oe addea to t~e reconstituted toDacco in order to: 1) increase tbe volume of the reconstituted tobacco s~eet without t~e need of using more tobacco components, ana 2) modify the comDustibility of the reconstituted tobacco sheet. T~e non-tobacco extenders can ~e incorporated into tbe to~acco components at virtually any step in the process. For example, t~e non-to~acco extenders can oe added to t~e tobacco stems in the fi~rillation stage 12, at t~e mixing stage 14 or at the sheet forming stage 16.
A wide variety of material or synthetic binaers are suitaDle for use in t~e present invention provided that they are not inimical to t~e flavor of tbe tobacco. Specific examples of such suitable Dinders include natural vegeta~le gums suc~ as, for example, gum arabic, gum tragacanth, guar gum, locust bean gum, etc. Other suitable gums include carbo~ydrate gums from animal sources, such as glycogen, deaceteylated c~itin and t~e like, marine plant gums suc~ as algins, carageenans, and agar.
Il ~2~
Preferred binders which are particularly advantageous in the met~od of tbe present invention include treated cellulosic gums, such as cellulose et~ers, cellulose esters, and mixtures t~ereof. Specific examples of such binders include met~yl cellulose, ethyl cellulose, hydroxypropyl cellulose, methylhydroxyethyl cellulose, ethylbydroxyethyl cellulose, cellulose acetate, hydroxyethyl cellulose, so~ium carboxymethyl cellulose, etc.
Specific examples of forming smoking tooacco material according to the process of the present invention are as follows:
A 5û/5û mixture of flue-cured tooacco and ourley tooacco stems having approximately 12 percent moisture content by weig~t were passed throug~ a double disc refiner to produce a shredde~ product of hig~ly fiorillated fioers. Twenty grams of tbis mixture was mixed with thirty grams of cigarette tooacco waste fines ~aving a 12 percent moisture content oy weight, five grams of flue-cured lamina fines of -14 mesh and ~aving a 12 percent moisture content, and five grams of burley lamina fines of -14 mesh and having a 12 percent moisture content. T~e tooacco fines and the fibrillated tobacco stem mixture were tumbled together to evenly distribute the fiorillate~ stems throug~out the mixture ar,d to separate tbe intertwinea bundles or clumps of stem fibers to form a homogenous mixture. The homogenous mixture was conveyed in an air stream to, and impacted on, a 170 U.S. mesh screen under which a vacuum of 21 inches of Hg. was applied. T~e homogenous mixture was thereby evenly distriouted on the screen to a t~ickness of approximately 20 mils to form a sheet or mat of interlaced fibrillated stem fibers and toDacco fines. Twenty ll !
~1 ml of a 5 percent solution of NaCMC Grade 7LF sold ~y Hercules ! Chemical Co. was then sprayed on the sheet as a oinder. The sheet was next dried in a forced draft oven at 100C. After the sheet of reconstituted to~acco was dried, it was mixed ~ith regular strip tooacco an~ cut and formed into cigarettes.
¦ A reconstituted tonacco sheet is prepared on a mesh screen as in Example 1. The tobacco sheet is removed from the screen and passed through a pair of calender rolls to reduce the sheet thickness from 20 mils to 10 mils. From the calender rolls, the tooacco sheet of reduced thickness is dried in a forced draft oven at lû0C. The driea sheet of reconstituted tooacco is then mixea with tooacco stems, cut, ana formea into a cigarette.
Fifty grams of Pectic enzyme is dissolved in 300 grams of water. This solution is sprayed on 500 grams of flue-cured stems to raise the total moisture content of t~e stems to aoout 60 percent oy weig~. The enzyme treated stems are then maintained at aoout 25C for from 24 to 48 hours to allow the pectic enzyme to oreak down the pectin contained in the stems.
The pectins are the "glue" wbich hold the fioers of the stems together. After the stems are treated for a sufficient lengtb of time to break down and loosen the fibers, the stems are passed through a double disc refiner to proauce fiorillated, !l individual fioers. Next, 100 grams of the flue-cured lamina fines are added to the 50n grams of fiorillatea treatea stems, and mixed together to uniformly distrioute fibrillated stems and lamina fines and form a bomogenous mixture. This homogenous mixture is then conveyed in an air stream to, and impacted on a mesb screen wbich has a vacuum chamber Il, Il Il _g_ Il ~ 6~
therebeneath. The vacuum created by tne vacuum chamber beneath t~e homogenous mixture, and the force of impact of t~e tobacco mixture as it is ~lown on the screen cause the homogeneous mixture to form into a felt-like sheet or mat of intertwined fi~rillatea tobacco-stems with toDacco fines uniformly dispersed t~erethrough. T~e pectines liberated by t~e action of t~e pectic enzymes on t~e toDacco stems functioned as a "glue" to ~ond t~e intertwined, fibrillated tobacco stems and tobacco fines toge~her and form a reconstituted tonacco leaf on the s~eet. T~e sheet of reconstituted to~acco s~eet is removed from t~e mes~ screen and suDjected to ~eated air at 100C for a sufficient time to reduce t~e moisture content to a~out 12 percent ~y weight. T~e reconstituted toDaCco sheet is then passed t~rough cutters to produce discreet particles ~hich are added to cut leaf tobacco and formed into a cigarette.
A mixture of tobacco stem fibers and to~acco is prepareû as in Example 1. To this mixture is added 20 gms. of cellulose fioers prepared in a similar manner as tobacco stems.
The resulting blend of tobacco and cellulose is then tumbled together to distri~ute t~e cellulose fi~ers uniformly.
The mixture was t~en formed to a reconstituted to~acco in the same manner as in Example 1.
A portion of the mixture as per Example 4 is mixe~
wit~ an additional 20 gms. alumina tri-~ydrate (A1203.3H20) and that mixture is formed into an extended to~acco as per Example 1.
A reconstituted tooacco is prepared and formed as per Example 1. After the ~inder has oeen added, calcium car~onate 12~
.1 .
(CaC03) is dusted on top. The sheet is then dried and removed from the wire as per Example 1.
A reconstituted tobacco mat is formed on a wire as per Example 1 but at only 1/2 the thickness. After the Dinder has been a~ded, a second mixture prepared as per Example 5 is Dlown on top in a similar manner as per Example 1 to form a laminated s~eet. The laminated sheet is then dried and removed from the wire as per Example 1.
The foregoing detailed description is given primarily for clearness of understanding and no unnecessary limitations are to De understood therefrom for modifications will oecome oDvious to those skilled in t~e art upon reading this disclosure and may De made without departing from the spirit of the invention and scope of the appended claims.
11 , ""-
Claims (18)
1. A method for manufacturing reconstituted tobacco of tobacco stems and tobacco fines comprising:
(a) treating the stem parts of tobacco in essentially a dry form to reduce the stem to substantially fibrous form;
(b) mixing the fibrous stem with fine lamina tobacco;
(c) conveying the mixture in an air stream and subsequently depositing the mixture of fibrous stem and fine lamina tobacco on a moving wire mesh continuous belt;
(d) passing said air stream through the tobacco mixture on the wire mesh belt for homogenizing the fibrous stem and fine tobacco lamina throughout the mixture and causing intertwining of the fibrous stems and forming a continuous non-woven felt sheet of fibrous stem and fine lamina tobacco;
(e) applying a binder to the non-woven felt sheet of fibrous stem and fine lamina tobacco as the felt sheet continues to move on the wire mesh belt;
(f) drying the binder; and, (g) removing said non-woven felt sheet of fibrous stem and fine lamina tobacco from the wire mesh belt in such a form for use in the manufacture of tobacco smoking articles.
(a) treating the stem parts of tobacco in essentially a dry form to reduce the stem to substantially fibrous form;
(b) mixing the fibrous stem with fine lamina tobacco;
(c) conveying the mixture in an air stream and subsequently depositing the mixture of fibrous stem and fine lamina tobacco on a moving wire mesh continuous belt;
(d) passing said air stream through the tobacco mixture on the wire mesh belt for homogenizing the fibrous stem and fine tobacco lamina throughout the mixture and causing intertwining of the fibrous stems and forming a continuous non-woven felt sheet of fibrous stem and fine lamina tobacco;
(e) applying a binder to the non-woven felt sheet of fibrous stem and fine lamina tobacco as the felt sheet continues to move on the wire mesh belt;
(f) drying the binder; and, (g) removing said non-woven felt sheet of fibrous stem and fine lamina tobacco from the wire mesh belt in such a form for use in the manufacture of tobacco smoking articles.
2. The method of claim 1 wherein the binder material comprises treated cellulosic gum.
3. The method of claim 2 wherein the treated cellulosic gum is selected from the group consisting of:
cellulose ethers, cellulose esters, and mixtures thereof.
cellulose ethers, cellulose esters, and mixtures thereof.
4. The method of claim 3 wherein the binder material is selected from the group consisting of:
methyl cellulose, ethyl cellulose hydroxypropyl cellulose, methylhydroxyethyl cellulose, ethylhydroxyethyl cellulose, cellulose acetate, hydroxyethyl cellulose, and sodium carboxymethyl cellulose.
methyl cellulose, ethyl cellulose hydroxypropyl cellulose, methylhydroxyethyl cellulose, ethylhydroxyethyl cellulose, cellulose acetate, hydroxyethyl cellulose, and sodium carboxymethyl cellulose.
5. The method of claim 1 wherein the binder comprises a natural vegetable gum.
6. The method of claim 5 wherein the natural vegetable gum is selected from the group consisting of:
gum arabic, gum tragacanth, guar gum, locust bean gum, and mixtures thereof.
gum arabic, gum tragacanth, guar gum, locust bean gum, and mixtures thereof.
7. The method of claim 1 wherein the binder comprises carbohydrate gums.
8. The method of claim 7 wherein the carbohydrate gum is selected from the group consisting of:
glycogen, deaceteylated chitin, and mixtures thereof.
glycogen, deaceteylated chitin, and mixtures thereof.
9. The method of claim 1 wherein the binder comprises a marine plant gum.
10. The method of claim 9 wherein the marine plant gum is selected from the group consisting of:
algins, carageenans, agar and mixtures thereof.
algins, carageenans, agar and mixtures thereof.
11. The method according to claim 1 wherein the non-woven felt of fibrous stem and lamina material are passed through calender rolls before being removed from said continuous wire belt.
12. A method for manufacturing reconstituted tobacco of tobacco stems and tobacco fines comprising:
(a) treating the stem parts of tobacco in essentially dry form to reduce the stem to substantially fibrous form;
(b) treating one or the other of the fibrous tobacco stem or fine lamina tobacco with a suitable chemical, or enzyme to liberate natural pectin material as a binder;
(c) mixing the fibrous stem with fine lamina tobacco;
(d) conveying the mixture in an air steam and subsequently depositing the mixture of fibrous stem and the fine lamina tobacco on a moving wire continuous belt;
(e) passing said air steam through the tobacco mixture on the wire mesh belt for homogenizing the fibrous stem and fine tobacco lamina throughout the mixture and causing intertwining of the fibrous stem and forming a continuous non-woven felt sheet of fibrous stem tobacco and fine lamina tobacco;
(f) drying the binder; and, (g) removing said non-woven felt sheet of fibrous tobacco stem and fine lamina tobacco in such a form for use in the manufacture of tobacco smoking articles.
(a) treating the stem parts of tobacco in essentially dry form to reduce the stem to substantially fibrous form;
(b) treating one or the other of the fibrous tobacco stem or fine lamina tobacco with a suitable chemical, or enzyme to liberate natural pectin material as a binder;
(c) mixing the fibrous stem with fine lamina tobacco;
(d) conveying the mixture in an air steam and subsequently depositing the mixture of fibrous stem and the fine lamina tobacco on a moving wire continuous belt;
(e) passing said air steam through the tobacco mixture on the wire mesh belt for homogenizing the fibrous stem and fine tobacco lamina throughout the mixture and causing intertwining of the fibrous stem and forming a continuous non-woven felt sheet of fibrous stem tobacco and fine lamina tobacco;
(f) drying the binder; and, (g) removing said non-woven felt sheet of fibrous tobacco stem and fine lamina tobacco in such a form for use in the manufacture of tobacco smoking articles.
13. The method of claim 1 wherein the moisture of said stem is from about 10% to about 60% before said treatment.
14. The method of claim 1 comprising the further step of adding a non-tobacco extender material to the stem parts.
15. The method of claim 1 comprising the further step of adding a non-tobacco extender material to the fine lamina tobacco.
16. The method of claim 1 comprising the further step of adding a non-tobacco extender material to the non-woven felt sheet of fibrous stem and lamina particles.
17. The method of claim 1 comprising the further step of adding a non-tobacco extender material to the mixture of fibrous stem and fine lamina tobacco.
18. A method for manufacturing reconstituted tobacco of tobacco stem and tobacco fines comprising:
(a) treating the stem parts of tobacco in essentially a dry form to reduce the stem to substantially fibrous form;
(b) mixing the fibrous tobacco stem with fine lamina tobacco;
(c) adding a binder to the stem and fine lamina tobacco as the stem and fine lamina tobacco are being mixed;
(d) conveying the mixture in an air stream and subsequently depositing the mixture of fibrous tobacco stem and fine lamina tobacco on a moving wire mesh continuous belt;
(e) passing said air steam through the tobacco mixture on the wire mesh belt for homogenizing the fibrous stem and fine tobacco lamina throughout the mixture and causing intertwining of the fibrous stem and forming a continuous non-woven felt sheet of intertwined fibrous stem and fine lamina tobacco;
(f) drying the binder; and, (g) removing said non-woven felt sheet of fibrous tobacco stem and fine lamina tobacco in such a form for use in the manufacture of tobacco smoking articles.
(a) treating the stem parts of tobacco in essentially a dry form to reduce the stem to substantially fibrous form;
(b) mixing the fibrous tobacco stem with fine lamina tobacco;
(c) adding a binder to the stem and fine lamina tobacco as the stem and fine lamina tobacco are being mixed;
(d) conveying the mixture in an air stream and subsequently depositing the mixture of fibrous tobacco stem and fine lamina tobacco on a moving wire mesh continuous belt;
(e) passing said air steam through the tobacco mixture on the wire mesh belt for homogenizing the fibrous stem and fine tobacco lamina throughout the mixture and causing intertwining of the fibrous stem and forming a continuous non-woven felt sheet of intertwined fibrous stem and fine lamina tobacco;
(f) drying the binder; and, (g) removing said non-woven felt sheet of fibrous tobacco stem and fine lamina tobacco in such a form for use in the manufacture of tobacco smoking articles.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US61216684A | 1984-05-21 | 1984-05-21 | |
| US612,166 | 1984-05-21 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1246418A true CA1246418A (en) | 1988-12-13 |
Family
ID=24452006
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000481819A Expired CA1246418A (en) | 1984-05-21 | 1985-05-17 | Process for manufacturing reconstituted tobacco |
Country Status (7)
| Country | Link |
|---|---|
| AU (1) | AU550267B2 (en) |
| BR (1) | BR8502338A (en) |
| CA (1) | CA1246418A (en) |
| DE (1) | DE3518254A1 (en) |
| FR (1) | FR2564294B1 (en) |
| GB (1) | GB2159036B (en) |
| IT (1) | IT1183629B (en) |
Families Citing this family (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4542755A (en) * | 1984-05-25 | 1985-09-24 | Kimberly-Clark Corporation | Dry-forming of reconstituted tobacco and resulting product |
| US4787402A (en) * | 1986-02-03 | 1988-11-29 | R. J. Reynolds Tobacco Company | Process and apparatus for providing roll reconstituted tobacco material |
| EP2989905B1 (en) * | 2014-04-17 | 2018-03-14 | Guangdong Golden Leaf Technology Development Co., Ltd. | Apparatus for producing reconstituted tobacco sheet via dry paper-making method |
| DE102018123911A1 (en) * | 2018-09-27 | 2020-04-02 | Hauni Maschinenbau Gmbh | Flat sheet of reconstituted tobacco material and method for producing such a flat sheet |
| BR112021011672A2 (en) * | 2018-12-18 | 2021-09-08 | Philip Morris Products S.A. | METHOD AND APPARATUS FOR PRODUCING A SHEET OF A MATERIAL CONTAINING ALKALOIDS |
| CN110693066B (en) * | 2019-11-11 | 2023-05-12 | 云南中烟工业有限责任公司 | Forming system and method for preparing reconstituted tobacco sheets by self-demolding casting method |
| CN115644488B (en) * | 2022-11-07 | 2024-06-11 | 上海烟草集团有限责任公司 | Preparation method of reconstituted tobacco |
Family Cites Families (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2887414A (en) * | 1958-03-06 | 1959-05-19 | American Mach & Foundry | Smoking product and method of manufacture |
| US3379198A (en) * | 1965-06-09 | 1968-04-23 | Liggett & Myers Tobacco Co | Coherent tobacco strip and the process for preparing the same |
| GB1157574A (en) * | 1965-10-27 | 1969-07-09 | Rothmans Of Pall Mall | Method of incorporating Fine Powders into a Polymeric Mass |
| CH459036A (en) * | 1967-02-09 | 1968-06-30 | Reemtsma H F & Ph | Method and device for the production of a strip-like material using a fibrous carrier substance and a dust, in particular for the production of tobacco foils |
| DE2055672C3 (en) * | 1970-11-12 | 1983-06-01 | Eduard Gerlach GmbH Chemische Fabrik, 4990 Lübbecke | Process for the production of a tobacco foil |
| DE2421652C3 (en) * | 1974-05-04 | 1984-01-19 | Eduard Gerlach GmbH Chemische Fabrik, 4990 Lübbecke | Process for the production of tobacco foils and plant for carrying out the process |
| US3968804A (en) * | 1974-05-20 | 1976-07-13 | Amf Incorporated | Extruded tobacco sheet |
| FR2371156A1 (en) * | 1976-11-18 | 1978-06-16 | Seita | PROCESS FOR TRANSFORMATION OF TOBACCO INTO COHERENT AGGREGATES |
| US4182349A (en) * | 1977-11-04 | 1980-01-08 | Kimberly-Clark Corporation | Method of making reconstituted tobacco |
-
1985
- 1985-05-01 AU AU41872/85A patent/AU550267B2/en not_active Ceased
- 1985-05-16 GB GB08512432A patent/GB2159036B/en not_active Expired
- 1985-05-17 CA CA000481819A patent/CA1246418A/en not_active Expired
- 1985-05-17 BR BR8502338A patent/BR8502338A/en not_active IP Right Cessation
- 1985-05-20 FR FR858507539A patent/FR2564294B1/en not_active Expired - Lifetime
- 1985-05-21 DE DE19853518254 patent/DE3518254A1/en active Granted
- 1985-05-21 IT IT20801/85A patent/IT1183629B/en active
Also Published As
| Publication number | Publication date |
|---|---|
| AU4187285A (en) | 1985-11-28 |
| BR8502338A (en) | 1986-01-21 |
| DE3518254C2 (en) | 1989-03-30 |
| FR2564294A1 (en) | 1985-11-22 |
| IT1183629B (en) | 1987-10-22 |
| GB2159036A (en) | 1985-11-27 |
| GB2159036B (en) | 1988-01-20 |
| AU550267B2 (en) | 1986-03-13 |
| DE3518254A1 (en) | 1985-11-21 |
| IT8520801A0 (en) | 1985-05-21 |
| FR2564294B1 (en) | 1990-09-28 |
| GB8512432D0 (en) | 1985-06-19 |
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