阅读说明：本技术 包括含有生物碱的均质化材料的片材的制备方法以及包含由其制备的组分的气溶胶形成制品 (Method for producing a sheet comprising homogenized material containing alkaloids and aerosol-forming article comprising components produced thereby ) 是由 M·加里奥尔特 C·勒叙夫勒尔 A·西博兹 于 2018-12-12 设计创作，主要内容包括：本发明涉及一种用于制备包括含有生物碱的均质化材料的片材的方法,所述方法包括：-形成包含含有生物碱的材料的颗粒与淀粉组分和一定量的第一添加剂的混合物,所述第一添加剂包含选自由水、气溶胶形成剂和粘合剂组成的组的组分,其中所述第一添加剂的所述量按重量计占所述混合物的总重量的约0.1％至约50％；-向所述混合物施加每千克所述混合物至少约20瓦时的机械能；-将所述混合物与一定量的第二添加剂组合以形成浆料,所述第二添加剂包含选自由水、气溶胶形成剂和粘合剂组成的组的组分；以及-由所述浆料形成片材。(The invention relates to a method for preparing a sheet comprising homogenized material containing alkaloids, the method comprising: -forming a mixture comprising particles of an alkaloid containing material and a starch component and an amount of a first additive comprising a component selected from the group consisting of water, an aerosol former and a binder, wherein the amount of the first additive comprises from about 0.1% to about 50% by weight of the total weight of the mixture; -applying mechanical energy of at least about 20 watt-hours per kilogram of the mixture to the mixture; -combining the mixture with an amount of a second additive comprising a component selected from the group consisting of water, an aerosol former, and a binder to form a slurry; and-forming a sheet from the slurry.)

1. A method for preparing a sheet comprising homogenized material containing alkaloids, the method comprising:

-forming a mixture comprising particles of an alkaloid containing material and starch and an amount of a first additive comprising a component selected from the group consisting of water, an aerosol former and a binder, wherein the amount of the first additive comprises from about 0.1% to about 50% by weight of the total weight of the mixture;

-applying mechanical energy of at least about 20 watt-hours per kilogram of the mixture to the mixture;

-combining the mixture with an amount of a second additive comprising a component selected from the group consisting of water, an aerosol former and a binder to form a slurry; and

-forming a sheet from the slurry.

2. The method of claim 1, wherein the second additive is added after the mechanical energy has been applied to the mixture.

3. The method of claim 1 or 2, wherein combining the mixture with an amount of a second additive comprising a component selected from the group consisting of water, an aerosol former, and a binder to form a slurry comprises:

-combining the mixture with an amount of water comprising from about 55% to about 90% by weight of the total weight of the slurry.

4. The method according to any one of the preceding claims, wherein the particles of alkaloid containing material have an average size comprised between about 0.02 mm and about 0.3 mm.

5. The method of any one of the preceding claims, wherein the step of forming a mixture comprises adding a reducing sugar in an amount of from about 2% to about 30% per weight of the mixture on a dry basis.

6. The method of any one of the preceding claims, wherein the step of applying mechanical energy to the mixture comprises:

-extruding the mixture.

7. The method of any one of the preceding claims, wherein the step of applying mechanical energy to the mixture of at least about 20 watt-hours per kilogram of the mixture is performed at a temperature of less than or equal to about 190 degrees celsius.

8. The method of any one of the preceding claims, wherein the step of applying mechanical energy of at least about 20 watt-hours per kilogram of the mixture to the mixture is applied for a time of between about 10 seconds and about 80 seconds.

9. The method of any preceding claim, wherein the step of combining the mixture with an amount of a second additive comprising a component selected from the group consisting of water, an aerosol former, and a binder to form a slurry comprises adding an amount of the second additive that comprises from about 150% to about 600% per weight of the slurry on a dry weight basis.

10. The method of any one of the preceding claims, wherein the step of combining the mixture with an amount of a second additive comprising a component selected from the group consisting of water, an aerosol former, and a binder to form a slurry such that the slurry comprises from about 45% to about 93% of the particles of the alkaloid containing material on a dry basis.

11. The method of any preceding claim, wherein the step of combining the mixture with an amount of a second additive comprising a component selected from the group consisting of water, an aerosol former, and a binder to form a slurry such that the slurry comprises from about 1% to about 10% of the binder on a dry weight basis.

12. The method of any preceding claim, wherein the step of combining the mixture with an amount of a second additive comprising a component selected from the group consisting of water, an aerosol former, and a binder to form a slurry such that the slurry comprises from about 5% to about 30% of the aerosol former on a dry weight basis.

13. The method of any preceding claim, wherein the step of combining the mixture with an amount of a second additive comprising a component selected from the group consisting of water, an aerosol former, and a binder to form a slurry such that the slurry comprises from about 150% to about 500% water on a dry weight basis.

14. The method according to any of the preceding claims, comprising:

-adding cellulose fibres to the alkaloid containing material.

15. The method of any one of the preceding claims, wherein the alkaloid containing material is a tobacco material.

16. The method according to any of the preceding claims, comprising the step of drying the sheet comprising the homogenized material containing alkaloids.

17. An aerosol-forming article comprising the components produced by the method of claims 1-16.

Technical Field

The present invention relates to a method for producing a sheet comprising a homogenized material comprising an alkaloid, such as a homogenized tobacco material, and to an aerosol-forming article comprising components prepared therefrom.

Background

Homogenized tobacco material is also used today when manufacturing tobacco products other than tobacco leaves. Such homogenized tobacco material is typically manufactured from tobacco plant parts, such as tobacco stems or tobacco dust, which are not well suited for the production of cut filler. Typically, tobacco dust is generated as a by-product in the processing of tobacco leaves during manufacture.

The starting material for producing the homogenized tobacco material for aerosol-generating articles may also be mainly tobacco leaves, which thus have the same dimensions and physical characteristics as tobacco in order to blend the cut filler.

Possible forms of homogenized tobacco material include reconstituted tobacco sheet and cast lamina. The process of forming a sheet of homogenised tobacco material generally comprises the step of mixing ground tobacco with a binder to form a slurry. The slurry is then used to form a tobacco web or sheet, for example by casting a viscous slurry onto a moving metal belt to produce a so-called cast leaf. Alternatively, a slurry having a low viscosity and a high moisture content can be used to produce reconstituted tobacco in a process similar to papermaking.

The sheet or web of homogenised tobacco material is typically scraped from a moving metal belt and then rolled into a roll that needs to be unwound for further processing and included as an aerosol-forming substrate in an aerosol-forming article.

In terms of its productivity, it may be desirable to improve or modify the process of forming the sheet comprising homogenized tobacco material.

Indeed, sheets comprising homogenized tobacco material may be difficult to handle and store due to their compactness, sensitivity to heat, stickiness or low tensile strength: it may easily tear and the sheet may break if the sheet is handled with too much force. For example, a sheet of homogenized tobacco material may be difficult to remove from a moving metal band in which it is positioned, or difficult to unwind when wound in a roll.

In addition, the rolls comprising the sheet of homogenized tobacco material may also be difficult to transport. Furthermore, they are preferably used within a very short time frame, since otherwise the windings of the sheet of homogenized tobacco material may stick together and may impair unwinding. Therefore, building a safe inventory of such bobbins can also be a difficult task.

Thus, there is a need for a process for producing a sheet of alkaloid containing material that is easily removed from the moving belt to which it is transported. There is a need for a process for producing sheets of alkaloid containing material which are easy to unwind from a roll and thus allow to provide a continuous, constant and regular feed of material to downstream equipment so that the rest of the production line can increase the overall productivity and thus the yield.

Disclosure of Invention

The present invention may meet at least one of the above needs.

In one aspect, the invention relates to a method for preparing a sheet comprising homogenized material containing alkaloids, the method comprising: forming a mixture comprising particles of an alkaloid containing material and starch and an amount of a first additive comprising a component selected from the group consisting of water, an aerosol former, and a binder, wherein the amount of the first additive is from about 0.1% to about 50% by weight of the total weight of the mixture; applying mechanical energy of at least about 20 watt-hours per kilogram of the mixture to the mixture; combining the mixture with an amount of a second additive to form a slurry, the second additive comprising a component selected from the group consisting of water, an aerosol former, and a binder; and forming a sheet from the slurry.

In another aspect, the invention relates to a method for preparing a sheet comprising homogenized material containing alkaloids, the method comprising: forming a mixture comprising granules of an alkaloid containing material with starch and an amount of water, the water comprising from about 0.1% to about 50% by weight of the total weight of the mixture; applying mechanical energy of at least about 20 watt-hours per kilogram of the mixture to the mixture; combining the mixture with an amount of a second additive to form a slurry, the second additive comprising a component selected from the group consisting of water, an aerosol former, and a binder; and forming a sheet from the slurry.

In another aspect, the invention relates to a method for preparing a sheet comprising homogenized material containing alkaloids, the method comprising: forming a mixture comprising granules of an alkaloid containing material with starch and a first amount of water, the first amount of water comprising from about 0.1% to about 50% by weight of the total weight of the mixture; applying mechanical energy of at least about 20 watt-hours per kilogram of the mixture to the mixture; forming a slurry by combining the mixture with a second amount of water, the second amount of water comprising about 55% to about 90% by weight of the total weight of the slurry; and forming a sheet from the slurry.

In the method of the invention, a mixture is formed comprising an alkaloid containing material and starch and an amount of a first additive comprising a component selected from the group consisting of water, an aerosol former, and a binder. In such a mixture, the first additive is present in an amount of about 0.1% to about 50% by weight based on the total weight of the mixture.

At least about 20 watt-hours of mechanical energy per kilogram of the mixture is applied to the mixture. Without being bound by theory, under these conditions the first additive may interact and may modify the starch comprised in the alkaloid containing material such that the resulting mixture, when combined with the second additive comprising a component selected from the group consisting of water, aerosol former and binder to form a slurry, may result in the sheet exhibiting improved properties with respect to compactness, sensitivity to heat, tack or tensile strength.

As used herein, the term "sheet" means a laminated element having a length and a length substantially greater than its thickness. The width of the sheet is preferably greater than about 10 mm, more preferably greater than about 20 mm or about 30 mm. Even more preferably, the width of the sheet is comprised between about 100 mm and about 300 mm.

An "alkaloid containing material" is a material that contains one or more alkaloids. The alkaloid may comprise nicotine. Nicotine may be present in, for example, tobacco. The alkaloid containing material is preferably tobacco.

Alkaloids are a group of naturally occurring compounds that contain primarily basic nitrogen atoms. This group also includes some related compounds that are neutral or even weakly acidic. Some synthetic compounds with similar structures are also known as alkaloids. In addition to carbon, hydrogen and nitrogen, alkaloids may also contain oxygen, sulfur, and, more rarely, other elements such as chlorine, bromine and phosphorus.

Alkaloids are produced by a variety of organisms including bacteria, fungi, plants, and animals. They can be purified from crude extracts of these organisms by acid-base extraction. Caffeine, nicotine, theobromine, atropine, tubocurarine are examples of alkaloids.

As used herein, "starch" is a portion of the material that contains alkaloids. It may also be added separately.

Starch is a polymeric carbohydrate, consisting of a large number of glucose units linked by glycosidic bonds. Starch is produced by most green plants as energy storage. It is the most common carbohydrate in the human diet and is contained in plants such as potato, wheat, maize (corn), rice and tobacco. It consists of two types of polymer molecules: linear and helical amylose and branched amylopectin, which are themselves arranged in semi-crystalline particles in plants. As used herein, the term "slurry" means a liquid, viscous or paste-like material, which may comprise an emulsion of different liquid, viscous or paste-like materials, and which may comprise a certain amount of solid particles, provided that the slurry still exhibits liquid, viscous or paste-like behavior.

As used herein, the term "homogenized tobacco material" refers to a material formed by agglomerating particulate tobacco, which contains the alkaloid nicotine. Thus, the alkaloid containing material may be a homogenized tobacco material.

The most commonly used forms of homogenized tobacco material are reconstituted tobacco sheets and cast leaves (cast leaf). The process to form the homogenized tobacco material sheet typically comprises the step of mixing tobacco dust with a binder to form a slurry. The slurry is then used to form a tobacco sheet. For example, so-called casting vanes are created by casting a viscous slurry onto a moving metal belt. Alternatively, a slurry having a low viscosity and a high moisture content can be used to produce reconstituted tobacco in a process similar to papermaking.

The sheet material of tobacco may be referred to as reconstituted sheet material and is formed using particulate tobacco (e.g., reconstituted tobacco) or a mixture of tobacco particles, humectant, and an aqueous solvent to form a tobacco composition. This tobacco composition may then be cast, extruded, rolled or pressed to form a sheet material from the tobacco composition. Sheets of tobacco may be formed using the following process: wet processes, in which shredded tobacco is used to make paper-like materials; or a cast leaf process, in which shredded tobacco and binder material are mixed together and cast onto a moving belt to form a sheet.

The sheet of homogenised tobacco material may then be rolled into a roll that needs to be unwound for further processing, for example to be part of, i.e. included in, an aerosol-forming substrate of an aerosol-forming article. In "heated non-burning" aerosol-generating articles, the aerosol-forming substrate is heated to a relatively low temperature to form an aerosol, but to prevent combustion of the tobacco material. Furthermore, the tobacco present in the homogenized tobacco sheet is typically only tobacco, or comprises a majority of the tobacco present in the homogenized tobacco material of such a "heat not burn" aerosol-generating article. This means that the aerosol composition produced by such a "heat-not-burn" aerosol-generating article is substantially based only on the homogenized tobacco material.

As used herein, the term "aerosol-forming material" refers to a material that is capable of releasing volatile compounds upon heating to produce an aerosol. Tobacco, together with other compounds, can be classified as an aerosol-forming material, in particular a sheet of homogenized tobacco comprising an aerosol former. The aerosol-forming substrate may comprise or consist of an aerosol-forming material.

The characteristics of the homogenized tobacco material may affect the process of forming a sheet comprising the material.

In fact, homogenized tobacco material is generally "sticky", that is to say, it is glued to an adjacent object and, at the same time, has a relatively low tensile strength, being quite fragile. Without being bound by theory, it is believed that such characteristics may be due to the presence of binders and aerosol forming agents, such as guar gum and glycerin, in the homogenized tobacco material.

According to the method of the present invention, a sheet of alkaloid containing material is produced.

A mixture of the alkaloid containing material and starch is formed and an amount of a first additive comprising a component selected from the group consisting of water, an aerosol former, and a binder.

In such a mixture, the first additive is present in an amount of about 0.1% to about 50% by weight based on the total weight of the mixture. The weight of the first additive is 0.1% to 50% of the total weight of the mixture.

Preferably, the weight ratio between the amount of the first additive and the amount of starch of the alkaloid containing material in the mixture (i.e. the ratio between the weight of the first additive and the weight of starch in the mixture) is comprised between about 2 and about 80.

Preferably, the amount of the first additive is from about 5% to about 40%, more preferably from about 10% to 30% by weight of the total weight of the mixture.

The mixture may comprise more than one first additive from the above group. Preferably, the particles and the first additive are mixed by any known means.

Preferably, the first additive is water. The amount of water in the mixture is from about 5% to about 30%, more preferably from about 10% to about 20%, even more preferably from about 10% to about 18% by weight of the total weight of the mixture.

Mechanical energy of at least about 20 watt-hours per kilogram of the mixture is then applied to the mixture.

The energy is applied by any known means, such as by stirring, mixing, or otherwise.

Under these conditions, the first additive interacts and possibly modifies the starch contained in the alkaloid containing material. Without intending to be bound by any particular theory, the first additive may interact with the amylose and amylopectin polymers of starch and may modify its crystalline and granular structure.

In this way, the starch modifies the properties of the resulting mixture, which is then combined with a second additive comprising a component selected from the group consisting of water, aerosol former, and binder to form a slurry. A sheet is then formed from the slurry, which sheet may exhibit the properties of solidity, sensitivity to heat, tack or tensile strength that are best used as components in aerosol-generating articles. In particular, the sheet may have improved tensile strength, or better heat resistance, or lower stickiness or better compactness when compared to a sheet formed from the same slurry, but wherein the starch component in the alkaloid containing material does not interact with a specific amount of the first additive under specific conditions of application of mechanical energy prior to sheet formation.

Preferably, the second additive is added after the mechanical energy is applied to the mixture.

Preferably, forming the slurry includes combining the mixture with an amount of water that is about 55% to about 90% by weight of the total weight of the slurry. The water may be the second additive or it may be added together with a further second additive.

Preferably, the step of forming a slurry comprises mixing the second additive with the mixture.

Further, the sheet may exhibit better surface characteristics when compared to a sheet formed from the same slurry, such as a smoother surface with fewer defects, but wherein the alkaloid containing material has not interacted with a particular amount of the first additive under particular conditions of application of mechanical energy prior to sheet formation.

Furthermore, the same slurry may show optimal characteristics with respect to its viscosity and density, which may also be kept time-stable.

Preferably, the particles of the alkaloid containing material have an average size comprised between about 0.02 mm and about 0.3 mm. More preferably, the average size is comprised between about 0.05 mm and about 0.2 mm.

An average size between about 0.02 mm and about 0.3 mm represents a size that can at least partially disrupt tobacco cells. The use of alkaloid containing material having such an average size advantageously results in a smooth and uniform slurry in downstream processing steps of the alkaloid containing material.

Preferably, the first additive comprises water.

Preferably, the first additive comprises a binder.

The binder used as the first additive may be any of the gums or pectins described below. For a descriptive review of glues that can be used as adhesives, see Gums And Stabilizers For The Food Industry, IRL Press (G.O.Phillip et al eds.1988) (glues And Stabilizers For The Food Industry, IRL Press, edited by G.O.Phillip et al, 1988); whistler, Industrial Gums: Polysaccharides And derivatives thereof, Academic Press, 2 nd edition, 1973); and Lawrence, Natural Gums For Edible polymers, Noyes Data Corp (1976) (Natural Gums For Edible Purposes, Noois Data Inc., 1976).

Although any binder may be used, preferred binders are natural pectins (such as fruit, citrus or tobacco pectins), guars (such as hydroxyethyl guar and hydroxypropyl guar), locust bean gums (such as hydroxyethyl and hydroxypropyl locust bean gums), alginates, starches (such as modified or derivatized starches), celluloses (such as methyl, ethyl, ethylhydroxymethyl and carboxymethyl celluloses), tamarind gum, dextrans, pullulan, konjac flour, xanthan gum and the like. A particularly preferred binder for the first additive is guar gum.

Preferably, the first additive comprises an aerosol former.

Suitable aerosol-forming agents as first additives are known in the art and include, but are not limited to: monohydric alcohols (such as menthol), polyhydric alcohols (such as triethylene glycol, 1, 3-butanediol and glycerol), esters of polyhydric alcohols (such as mono-, di-or triacetate glycerol) and fatty acid esters of mono-, di-or polycarboxylic acids (such as dimethyl dodecanedioate and dimethyl tetradecanedioate).

Examples of preferred aerosol formers are glycerol and propylene glycol.

Preferably, the step of forming a mixture comprises adding reducing sugars in an amount of about 2% to about 30% by dry weight per weight of the mixture, more preferably about 5% to about 25% by dry weight per weight of the mixture, more preferably about 10% to about 15% by dry weight per weight of the mixture, and even more preferably about 11% to about 14% by dry weight per weight of the mixture.

Reducing sugars can modify the alkaloid containing material upon application of mechanical energy to the mixture such that the resulting material has different properties with respect to the composition of the alkaloid containing material as compared to the alkaloid containing material without the addition of reducing sugars. These differences can affect the final properties of the sheet.

Reactions may occur between reducing sugars and alkaloid containing materials, particularly if the alkaloid containing material contains ammonia and ammonium containing compounds. The reaction changes the composition of the alkaloid containing material such that the resulting material has a lower amount of ammonia or ammonium containing compounds compared to the alkaloid containing material without added reducing sugars such that, for example, in terms of flavor, the aerosol generated from the material may thus exhibit desirable or different properties.

This amount of reducing sugar has proven to be optimal for obtaining the desired properties in the final product. For example, a desired content of ammonia can be obtained.

Preferably, the reducing sugar is selected from the group consisting of glucose, fructose, xylose, ribose, galactose, and mixtures thereof. More preferably, the reducing sugar is glucose, fructose, and mixtures thereof.

Preferably, the reducing sugar is mixed with the alkaloid containing material in powder form, in liquid form or in slurry form.

The alkaloid containing material may be in any desired form prior to mixing with the reducing sugar.

Preferably, the amount of the first additive is from about 10% to about 70% by dry weight of the starch component of the alkaloid containing material per weight, more preferably from about 20% to about 60% by dry weight of the starch component of the alkaloid containing material per weight, even more preferably from about 30% to about 50% by dry weight of the starch component of the alkaloid containing material.

Preferably, at least about 50 watt-hours per kilogram of the mixture of mechanical energy is applied to the mixture, more preferably at least about 100 watt-hours per kilogram of the mixture, more preferably at least about 150 watt-hours per kilogram of the mixture, more preferably between about 150 watt-hours per kilogram of the mixture and about 350 watt-hours per kilogram of the mixture, more preferably between about 200 watt-hours per kilogram of the mixture and about 300 watt-hours per kilogram of the mixture, and even more preferably between about 225 watt-hours per kilogram of the mixture and about 275 watt-hours per kilogram of the mixture.

Preferably, the mechanical energy applied is less than about 350 watt-hours per kilogram of mixture to avoid or minimize nicotine loss.

Preferably, the step of applying mechanical energy to the mixture comprises: the mixture is extruded.

Extrusion is a process used to create an object that pushes the material (in this case the mixture described above) through a die of the desired cross-section. The mixture in the mold is subjected to compressive and shear stresses. Thus, the mixture is pushed from the input end to the output end of the extruder while substantially absorbing energy.

Extrusion is the preferred means of applying mechanical energy to the mixture and may help to improve the interaction of the first additive with the starch component of the alkaloid containing material.

Preferably, the step of applying mechanical energy is performed at a temperature of less than or equal to about 190 degrees celsius, more preferably between about 30 degrees celsius and about 190 degrees celsius. More preferably, the maximum temperature reached during the step of applying energy is between about 140 degrees Celsius and about 190 degrees Celsius, even more preferably between about 175 degrees Celsius and about 185 degrees Celsius.

The extrusion temperature may affect the interaction between the first additive and the starch contained in the alkaloid containing material. This extrusion temperature in the extruder has proven to be optimal for obtaining the interaction between the first additive and the starch comprised in the alkaloid containing material.

Other processing conditions (such as extrusion time for extrusion) may also be relevant factors as it may also affect the interaction between the first additive and the starch in the alkaloid containing material.

Preferably, the step of applying mechanical energy is carried out for an application time comprised between about 10 seconds and about 80 seconds, more preferably between about 10 seconds and about 60 seconds, more preferably between about 15 seconds and about 50 seconds, more preferably between about 20 seconds and about 30 seconds, and even more preferably between about 22 seconds and about 27 seconds.

In the process of the present invention, the second additive may be the same as or different from the first additive.

Preferably, the second additive comprises water.

Preferably, the second additive comprises a binder. Preferably, the binder used in the second additive may be any of the gums or pectins described above in relation to the first additive. A particularly preferred binder for the second additive is guar gum.

Preferably, the second additive comprises an aerosol former. Preferably, the aerosol former used in the second additive may be any of the aerosol formers described above in relation to the first additive. Examples of preferred aerosol formers in the second additive are glycerol and propylene glycol.

Preferably, the second additive is present in an amount of from about 200% to about 550% by dry weight per weight of the slurry, more preferably from about 200% to about 500% by dry weight per weight of the slurry.

Preferably, the slurry comprises on a dry weight basis from about 45% to about 93% of particles of the alkaloid containing material. More preferably, the slurry comprises, on a dry weight basis, from about 65% to about 83% of particles of the alkaloid containing material.

Preferably, the slurry comprises, on a dry weight basis, from about 1% to about 10% binder. More preferably, the slurry comprises about 4% to about 8% binder by dry weight.

Preferably, the slurry comprises from about 5% to about 30% aerosol former by dry weight. More preferably, the slurry comprises from about 15% to about 25% aerosol former by dry weight.

Preferably, the slurry comprises from about 150% to about 500% water by dry weight.

Preferably, the water content of the slurry prior to the step of forming the sheet is between about 10% and about 90% per weight, more preferably between about 20% and about 80% per weight, even more preferably between about 40% and about 80% per weight, even more preferably between about 60% and about 80% per weight.

Preferably, in the method of the present invention, the step of forming the slurry comprises: the slurry is homogenized.

Preferably, in the method of the present invention, the step of homogenizing the slurry is performed at a temperature between about 20 degrees celsius and about 60 degrees celsius, more preferably between about 25 degrees celsius and about 55 degrees celsius.

Preferably, the method of the invention comprises adding cellulose fibres to the alkaloid containing material.

Cellulosic fibers can be introduced into the slurry. The introduction of cellulose fibers into the slurry generally increases the tensile strength of the alkaloid containing material and thus acts as a reinforcing agent. Thus, the addition of cellulose fibers may increase the resilience of the alkaloid containing material.

Cellulosic fibers for addition to alkaloid containing materials (such as homogenized tobacco material) are known in the art and include, but are not limited to: softwood fibers, hardwood fibers, jute fibers, flax fibers, tobacco fibers, and combinations thereof. In addition to pulping, the cellulosic fibers may be subjected to suitable processes such as refining, mechanical pulping, chemical pulping, bleaching, kraft pulping, and combinations thereof.

The cellulose fibers may include tobacco stem material, stems, or other tobacco plant material. Preferably, the cellulosic fibers (e.g., wood fibers) comprise a low lignin content. Alternatively, fibers, such as vegetable fibers, may be used with the above fibers or in alternatives including hemp and bamboo.

The length of the cellulose fibres is advantageously between about 0.2 mm and about 4 mm. Preferably, the cellulose fibers have an average length by weight of between about 1 millimeter and about 3 millimeters.

Further, preferably, the amount of cellulose fibers added to the alkaloid containing material, in addition to the cellulose fibers already present in the alkaloid containing material, is from about 1% to about 7% of the total weight of the pulp on a dry weight basis.

Preferably, the method of the invention comprises the step of adding additional alkaloid containing material to the slurry.

Preferably, the step of forming a sheet from the slurry comprises: the slurry is cast into a sheet.

Preferably, the method of the invention comprises the step of drying the sheet comprising the homogenized material containing the alkaloid.

Preferably, the water content of the sheet comprising homogenized material containing alkaloids after drying is between about 7% and about 15% per weight.

Preferably, the sheet comprising homogenized material containing alkaloids comprises, on a dry weight basis, from about 45% to about 93% of material containing alkaloids.

Preferably, the alkaloid containing material is a homogenized tobacco material. In such a case, the alkaloid contained in the material may comprise nicotine.

According to a second aspect, the present invention relates to an aerosol-forming article comprising components produced by a method according to the first aspect of the present invention.

The advantages of the second aspect have been outlined with reference to the first aspect and will not be repeated here.

Aerosol-forming articles according to the invention may be in the form of filter cigarettes or other smoking articles in which the tobacco material forms an aerosol upon combustion. The invention additionally encompasses articles in which the tobacco material is heated to form an aerosol rather than being combusted, and articles in which a nicotine-containing aerosol is generated from the tobacco material without combustion or heating.

The aerosol-forming article according to the invention may be an aerosol-forming article component, such as a consumable component of a heated smoking device, which is either wholly assembled or combined with one or more other components so as to provide an assembled article for generating an aerosol.

An aerosol-forming article may be an article that generates an aerosol that may be inhaled directly into the lungs of a user through the user's mouth. The aerosol-forming article may resemble a conventional smoking article such as a cigarette and may comprise tobacco. The aerosol-forming article may be disposable. Alternatively, the aerosol-forming article may be partially reusable and comprise a replenishable or replaceable aerosol-forming substrate.

The aerosol-forming article may also comprise a combustible cigarette. In a preferred embodiment, the aerosol-forming article may be substantially cylindrical in shape. The aerosol-forming article may be substantially elongate. The aerosol-forming article may have a length and a periphery substantially perpendicular to the length. The aerosol-forming article may have an overall length of between about 30 mm and about 100 mm. The aerosol-forming article may have an outer diameter of between about 5 millimetres and about 12 millimetres.

In all aspects of the invention, preferably, the alkaloid containing material is a homogenized tobacco material. In such a case, the alkaloid contained in the material may comprise nicotine.

Homogenized tobacco sheets include tobacco particles (e.g., tobacco stems and lamina) ground from tobacco leaves.

The homogenized tobacco sheet may also include small amounts of one or more of tobacco dust, tobacco fines, and other particulate tobacco by-products formed during processing, handling, and transport of the tobacco.

The tobacco present in the homogenized tobacco material may constitute a majority of the tobacco, or even substantially the total amount of tobacco present in the aerosol-generating article.

Drawings

Specific embodiments of the present invention will be further described, by way of example only, with reference to the accompanying drawings, in which:

figure 1 shows a flow chart of a method for producing a sheet comprising homogenized tobacco material according to the invention;

FIG. 2 shows a schematic side view of an extruder for producing an extrusion mixture; and is

Figure 3 shows the heat profile of an extruder used to produce the extrusion mixture.

Detailed Description

Referring first to figure 1, a method of producing a sheet of homogenised material containing alkaloids according to the invention is shown.

In a first step 100, a mixture of particles of an alkaloid containing material, a reducing sugar and a first additive is formed. The alkaloid containing material is a tobacco material containing the alkaloid nicotine. In addition, the tobacco comprises starch. The reducing sugar is fructose. The first additive is water.

Preferably, the mixture comprises (percentages by total weight of the mixture):

64% -82% tobacco powder;

8% -18% of added sugar;

10% -18% of added water.

The method comprises a further step 101, wherein the mixture is receiving energy, such as in an extruder 200 (shown in fig. 2) comprising an inlet 201 and an outlet 202. In the extruder 200, the mixture is moved along an extrusion direction defined between an inlet 201 and an outlet 202, indicated in fig. 2 by an arrow 203, and is subjected to a thermo-mechanical treatment.

Preferably, between about 180 and about 435 watt-hours of mechanical energy per kilogram of mixture is applied. More preferably, the mechanical energy is between about 225 watt-hours per kilogram of the mixture and about 275 watt-hours per kilogram of the mixture.

During the energy application, for example in an extruder, the reducing sugar preferably undergoes a reaction with the ammonia and ammonium containing compounds of the tobacco material. In addition, the starch present in tobacco also undergoes a reaction with water.

A schematic thermal profile along the extrusion direction 203 of the extrusion process of the method of the invention is shown in fig. 3. Extrusion is a possible example of energy application.

Step 101 of fig. 1 comprises a substep 301, wherein the mixture is fed to an extruder 200.

After sub-step 301, step 101 comprises a further sub-step 302: the mixture present within the extruder 200 is heated to a first temperature that is less than or equal to about 190 degrees celsius. Preferably, the first temperature is between about 90 degrees celsius and about 190 degrees celsius, more preferably between about 140 degrees celsius and about 190 degrees celsius, and even more preferably between about 175 degrees celsius and about 185 degrees celsius. Preferably, the heating is performed in the first section 204 of the extruder 200. Preferably, the residence time in the first section of the extruder is between about 18 seconds and about 22 seconds.

After substep 302 of heating the mixture to the first temperature, a further substep 303 is preferably performed: the mixture present within the extruder 200 is cooled from a first temperature to a second temperature that is less than or equal to about 70 degrees celsius. Preferably, the second temperature is between about 30 degrees celsius and about 70 degrees celsius, more preferably between about 35 degrees celsius and about 50 degrees celsius, and even more preferably between about 35 degrees celsius and about 45 degrees celsius. Preferably, cooling is performed in the second section 205 of the extruder 200 downstream of the first section 204 of the extruder 200 in the extrusion direction 203. Preferably, the residence time in the second section 205 of the extruder is between about 18 seconds and about 22 seconds.

As shown in fig. 3, the extruding step 101 may include maintaining the mixture at a first temperature, preferably within the first section 204 of the extruder 200, for a residence time prior to the step of cooling the mixture. Preferably, the residence time is comprised between about 6 seconds and about 40 seconds. More preferably, the residence time is between about 7 seconds and about 11 seconds.

After the step 303 of cooling the mixture from the first temperature to the second temperature, a further step 304 is performed: the mixture is discharged from the extruder 200 at a second temperature. Thus, the tobacco mixture has a lower amount of ammonia and ammonium containing compounds than the tobacco material prior to the extrusion process. Furthermore, starch may already react with water.

The extruded mixture preferably has these characteristics: the tobacco powder remained unchanged, whereas the slurry contained (percentages by weight)

5 to 8 percent of water, and the water,

2% -6% sugars (which have been reacted with ammonia).

After the extrusion step 101, the extruded mixture is used in a subsequent slurry preparation step 102.

Prior to or during the slurry preparation step 102, the method of the present invention may comprise two additional steps: a slurry preparation step 103 in which cellulose fibers 5 and water 6 are slurried to uniformly disperse and refine the fibers in the water; and a suspension preparation step 104, in which the aerosol former 7 and the binder 8 are premixed. Preferably, the aerosol former 7 comprises glycerol and the binder 8 comprises guar gum. Advantageously, the suspension preparation step 104 comprises premixing the guar gum and the glycerol without introducing water.

Slurry preparation step 102 preferably includes transferring the pre-mixed solution of aerosol former and binder to a slurry mixing tank and transferring the slurry to the slurry mixing tank. In addition, the slurry preparation step includes metering the extruded tobacco powder exiting from the extruder into a slurry mixing tank along with the slurry and guar-glycerin suspension. Additional tobacco powder may also be added. More preferably, this step further comprises processing the slurry with a high shear mixer to ensure homogeneity and homogeneity of the slurry.

Preferably, the slurry preparation step 102 further comprises a water addition step, wherein water is added to the slurry to obtain the desired viscosity and water content.

Preferably, the composition of the slurry is as follows:

the mixture exiting the extruder is mixed with cellulose fibers. The mixture obtained was mixed with (pre-mixed guar glycerol) and water to obtain the following slurry (percentages by weight):

-15% -30% of tobacco blend from the extrusion process;

-65% -75% water;

-0.5% -1.5% added cellulose fibres;

-0.1% -1% guar gum;

-2% -7% glycerol.

To form a sheet comprising homogenized tobacco material, the slurry formed according to step 102 is preferably cast in a casting step 105. Preferably, the casting step 105 comprises transporting the slurry to a casting station and casting the slurry into a sheet having a homogeneous and uniform thickness on a support. Preferably, the cast sheet thickness, water content and density are controlled immediately after casting during casting, and more preferably, the cast sheet thickness, water content and density are also continuously monitored and feedback controlled using a slurry measuring device during the entire process.

The homogenized cast sheet is then dried in a drying step 106, which includes drying the cast sheet uniformly and gently, for example, in an endless stainless steel belt dryer. The endless stainless steel belt dryer may comprise individually controllable zones. Preferably, the drying step comprises monitoring the cast sheet temperature at each drying zone to ensure a gentle drying profile at each drying zone, and heating the support in which the homogenized cast web is formed. Preferably, the drying profile is a so-called TLC drying profile.

At the end of the web drying step 106, a monitoring step (not shown) is performed to measure the moisture content and the number of defects in the dried web.

The sheet comprising homogenized tobacco that has been dried to a target water content is then drawn from the moving steel belt and preferably wound up in a winding step 107, for example to form a single main roll. Thanks to the improved characteristics of the sheet comprising homogenized tobacco according to the invention, it can be easily scraped or then unwound from the main reel without significant breakage of the sheet, thus increasing the productivity of the whole process. The main roll can then be easily used for the production of smaller rolls by means of slitting and log forming processes. The smaller bobbin may then be used to produce an aerosol-generating article (not shown).