Tobacco product and method for manufacture   

FIELD OF THE INVENTION

The present invention relates to products made or derived from tobacco, or that otherwise incorporate tobacco, and that are intended for human consumption.

BACKGROUND OF THE INVENTION

Cigarettes, cigars, and pipes are popular smoking articles that employ tobacco in various forms. Such smoking articles are used by heating or burning tobacco, and aerosol (e.g., smoke) may be inhaled by the smoker. Tobacco may also be enjoyed in a so-called “smokeless” form. Particularly popular smokeless tobacco products are employed by inserting some form of processed tobacco or tobacco-containing formulation into the mouth of the user.

Various types of smokeless tobacco products are set forth in U.S. Pat. Nos. 1,376,586 to Schwartz; 3,696,917 to Levi; 4,513,756 to Pittman et al.; 4,528,993 to Sensabaugh, Jr. et al.; 4,624,269 to Story et al.; 4,987,907 to Townsend; 5,092,352 to Sprinkle, III et al.; and 5,387,416 to White et al.; U.S. Pat. Appl. Pub. No. 2005/0244521 to Strickland et al.; PCT WO 04/095959 to Arnarp et al.; PCT WO 05/063060 to Atchley et al.; PCT WO 05/004480 to Engstrom; PCT WO 05/016036 to Bjorkholm; and PCT WO 05/041699 to Quinter et al., each of which is incorporated herein by reference. See also, for example, the types of smokeless tobacco formulations, ingredients, and processing methodologies set forth in U.S. Pat. Nos. 6,953,040 to Atchley et al. and 7,032,601 to Atchley et al.; U.S. Pat. Appl. Pub. Nos. 2002/0162562 to Williams; 2002/0162563 to Williams; 2003/0070687 to Atchley et al.; 2004/0020503 to Williams; U.S. Pat. Appl. Pub. Nos. 2005/0178398 to Breskin et al.; 2006/0191548 to Strickland et al.; 2007/0062549 to Holton, Jr. et al.; 2007/0186941 to Holton, Jr. et al.; 2007/0186942 to Strickland et at; 2008/0029110 to Dube et al.; 2008/0029116 to Robinson et al.; 2008/0029117 to Mua et al.; 2008/0173317 to Robinson et al.; 2008/0209586 to Neilsen et al.; 2009/0095313 to Fuisz and 2009/0293889 to Kumar et al.; and U.S. patent application Ser. No. 12/476,621, filed Jun. 2, 2009 to Chen et al.; each of which is incorporated herein by reference.

One type of smokeless tobacco product is referred to as “snuff.” Snuff typically is formulated in “moist” or “dry” forms. Representative types of moist snuff products, commonly referred to as “snus,” are manufactured in Europe, particularly in Sweden, by or through companies such as Swedish Match AB, Fiedler & Lundgren AB, Gustavus AB, Skandinavisk Tobakskompagni A/S, and Rocker Production AB. Snus products available in the U.S.A. have been marketed under the tradenames Camel Snus Frost, Camel Snus Original and Camel Snus Spice by R. J. Reynolds Tobacco Company. Representative smokeless tobacco products also have been marketed under the tradenames Oliver Twist by House of Oliver Twist A/S; Copenhagen, Skoal, SkoalDry, Rooster, Red Seal, Husky, and Revel by U.S. Smokeless Tobacco Co.; “taboka” by Philip Morris USA; and Levi Garrett, Peachy, Taylor\'s Pride, Kodiak, Hawken Wintergreen, Grizzly, Dental, Kentucky King, and Mammoth Cave by Conwood Sales Co., L.P. See also, for example, Bryzgalov et al., 1N1800 Life Cycle Assessment, Comparative Life Cycle Assessment of General Loose and Portion Snus (2005). In addition, certain quality standards associated with snus manufacture have been assembled as a so-called GothiaTek standard.

It would be desirable to provide in an efficient and effective mariner enjoyable forms of tobacco products, and to provide processes for preparing formed or extruded types of tobacco products.

SUMMARY

The present invention relates to products made or derived from tobacco, or that otherwise incorporate tobacco, and are intended for human consumption. Of particular interest, are tobacco products, compositions or formulations, and methods for providing, producing or assembling those tobacco products, compositions or formulations. Certain highly preferred tobacco products can be used in a so-called smokeless form, and are formulated and/or formed so as to be suitable for insertion into the mouth of the smokeless tobacco user.

The tobacco products incorporate binder systems. As such, tobacco materials (which can have various forms, and which can be comprised of various types of tobacco), as well as other suitable ingredients, are processed in the presence of a binder system during production or assembly. Of particular interest is a binder system that possesses or exhibits thermoplastic properties, characteristics or behaviors. The binder system can incorporate at least one type of binding agent that exhibits thermoplastic properties, characteristics or behaviors (e.g., the binding agent can be composed of at least one thermoplastic polymeric material). Additionally, the binder system can incorporate ingredients or materials so as to provide a binding agent that exhibits thermoplastic characteristics (e.g., the binding agent can be composed of at least one thermoplastic binding material in combination with a plasticizer). In certain embodiments, the thermoplastic binder system can be composed of at least one thermoplastic polymer material and a thermoplastic binding material in combination with at least one plasticizer. In certain highly preferred embodiments, the amount of thermoplastic polymeric material employed to produce a representative processed tobacco product can be no more than about 20 percent of the final formed product or formulation, on a dry weight basis. Thus, the present invention in one regard relates to a tobacco product in a form suitable for insertion into the mouth of a user, and comprises tobacco and thermoplastic binder system, wherein the amount of thermoplastic binder system being present in an amount less than about 30 weight percent of the dry weight of the tobacco product.

Certain preferred methods for providing, producing or assembling those tobacco products involve contacting tobacco, together with other desired ingredients, in the presence of a binder system, and forming the resulting mixture into a shape. In certain highly preferred embodiments, the method comprises process steps that involve extruding (or otherwise physically forming, such as by molding or casting) the mixture into the form of a strip, a sheet, a rod, a tube, or other desired shape. The mixing of the tobacco formulation involves contacting the tobacco being processed with a binder system that exhibits thermoplastic properties. The processing conditions associated with the production of the tobacco product are controlled so as to efficiently and effectively provide a tobacco product having desired physical and sensory characteristics (e.g., by controlling the temperature and/or pressure experienced by the mixture during processing conditions, the moisture and/or other solvent content of the mixture being processed, mixing conditions, or the like). Of particular interest are processing conditions that most preferably involve exposing a tobacco formulation to a temperature of less than about 100° C. during processing conditions (such as those experienced during extrusion), that involve use of a binding agent that can be employed in relatively low amounts, that involve use of a binding agent that exhibits desirable thermoplastic behavior (and hence can act to provide good physical integrity to the formed tobacco product) at processing conditions of less than about 100° C., and that involve the use of relatively low to moderate amounts of liquid processing aids (e.g., water or other liquid carriers). Thus, the present invention in one regard relates to a method for making a smokeless tobacco product comprising the steps of contacting tobacco material and thermoplastic binder system to provide a mixture; subjecting the mixture to elevated temperature; forming the mixture into a desired shape of a tobacco product; and cooling the tobacco product.

As will be realized by those of skill in the art, many different embodiments of tobacco products, and methods of making or assembling a tobacco product, are possible. Additional uses, advantages, and features of the tobacco product and methods of its manufacture are set forth in the illustrative embodiments in the detailed description herein and will become more apparent to those skilled in the art upon examination of the following.

DETAILED DESCRIPTION

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

Tobaccos used as tobacco materials for the preparation of tobacco products, compositions or formulations may vary. The tobaccos may include types of tobaccos such as flue-cured tobacco, burley tobacco, sun-cured tobacco (e.g., Oriental tobacco or Indian Kurnool), Maryland tobacco, dark tobacco, dark-fired tobacco, Indian air cured, dark air cured (e.g., passanda, cubano, jatin and bezuki tobaccos) or light air cured (e.g., North Wisconsin and galpoa tobaccos), and Rustica tobaccos, as well as other rare or specialty tobaccos or even green or uncured tobaccos. Descriptions of various types of tobaccos, growing practices, harvesting practices and curing practices are set forth in Tobacco Production, Chemistry and Technology, Davis et al. (Eds.) (1999), which is incorporated herein by reference. See, also, the types of tobaccos that are set forth in U.S. Pat. Nos. 4,660,577 to Sensabaugh, Jr. et al.; 5,387,416 to White et al.; and 6,730,832 to Dominguez et al., U.S. Patent Appl. Pub. Nos. 2006/0037623 to Lawrence, Jr. and PCT WO 2008/103935 to Nielsen et al.; each of which is incorporated herein by reference. Most preferably, the tobacco materials are those that have been appropriately cured and aged. Especially preferred techniques and conditions for curing flue-cured tobacco are set forth in Nestor et al., Beitrage Tabakforsch. Int., 20 (2003) 467-475 and U.S. Pat. No. 6,895,974 to Peele, which are incorporated herein by reference. Representative techniques and conditions for air curing tobacco are set forth in Roton et al., Beitrage Tabakforsch. Int., 21 (2005) 305-320 and Staaf et al., Beitrage Tabakforsch. Int., 21 (2005) 321-330, which are incorporated herein by reference. Certain types of unusual or rare tobaccos can be sun cured. Representative Oriental tobaccos include katerini, prelip, komotini, xanthi and yambol tobaccos. Tobacco compositions including dark air cured tobacco are set forth in U.S. Patent Appl. Pub. No. 2008/0245377 to Marshall et al., which is incorporated herein by reference.

Tobacco products may incorporate a single type of tobacco (e.g., in a so-called “straight grade” form). For example, the tobacco may be composed solely of flue-cured tobacco (e.g., all of the tobacco may be composed, or derived from, either flue-cured tobacco lamina or a mixture of flue-cured tobacco lamina and flue-cured tobacco stem). Tobacco products also (though most preferably) may have a so-called “blended” form. For example, the tobacco products may include composed of a mixture of parts or pieces of flue-cured, burley (e.g., Malawi burley tobacco) and Oriental tobaccos (e.g., as tobacco composed of, or derived from, tobacco lamina, or a mixture of tobacco lamina and tobacco stem). For example, a representative blend may incorporate about 30 parts to about 70 parts burley tobacco (e.g., lamina, or lamina and stem), and about 30 parts to about 70 parts flue cured tobacco (e.g., stem, lamina, or lamina and stem) on a dry weight basis. Other exemplary tobacco blends incorporate on a dry weight basis about 75 parts flue-cured tobacco, about 15 parts burley tobacco, and about 10 parts Oriental tobacco; or about 65 parts flue-cured tobacco, about 25 parts burley tobacco, and about 10 parts Oriental tobacco; or about 65 parts flue-cured tobacco, about 10 parts burley tobacco, and about 25 parts Oriental tobacco. Other exemplary tobacco blends incorporate about 20 to about 30 parts Oriental tobacco and about 70 to about 80 parts flue-cured tobacco. The tobacco that is processed in accordance with the present invention can have the form of previously processed tobacco parts or pieces, cured and aged tobacco in essentially natural lamina or stem form, tobacco extracts, extracted tobacco pulp (e.g., using water as a solvent), or a mixture of the foregoing (e.g., a mixture that combines extracted tobacco pulp with granulated cured and aged natural tobacco lamina, or a mixture that combines granulated tobacco lamina and stems with an aqueous tobacco extract). Portions of the tobaccos within the tobacco product may have processed forms, such as processed tobacco stems (e.g., cut-rolled stems, cut-rolled-expanded stems or cut-puffed stems), or volume expanded tobacco (e.g., puffed tobacco, such as dry ice expanded tobacco (DIET)). See, for example, the tobacco expansion processes set forth in U.S. Pat. Nos. 4,340,073 to de la Burde et al.; 5,259,403 to Guy et al.; and 5,908,032 to Poindexter, et al.; and U.S. Patent Appl. Pub. No. 2004/0182404 to Poindexter, et al., all of which are incorporated by reference. In addition, the tobacco product optionally may incorporate tobacco that has been fermented. See, also, the types of tobacco processing techniques set forth in PCT WO 05/063060 to Atchley et al., which is incorporated herein by reference.

The tobacco that is processed most preferably includes tobacco lamina, or tobacco lamina and stem mixture. Tobacco mixtures incorporating a predominant amount of tobacco lamina, relative to tobacco stem, are preferred. Most preferably, the tobacco lamina and stem are used in an unextracted form, that is, such that the extractable portion (e.g., the water soluble portion) is present within the unextractable portion (e.g., the tobacco pulp) in a manner comparable to that of natural tobacco provided in a cured and aged form.

The tobacco that is processed can have a shredded, ground, granulated, fine particulate, or powder form. The manner by which the tobacco is provided in a finely divided or powder type of form may vary. Preferably, tobacco parts or pieces are comminuted, ground or pulverized into a powder type of form using equipment and techniques for grinding, milling, or the like. Most preferably, the tobacco is relatively dry in form during grinding or milling, using equipment such as hammer mills, cutter heads, air control mills, or the like. For example, tobacco parts or pieces may be ground or milled when the moisture content thereof is less than about 15 weight percent to less than about 5 weight percent.

Most preferably, the tobacco that is processed can be employed in the form of parts or pieces that have an average particle size less than that of the parts or pieces of shredded tobacco used in so-called “fine cut” tobacco products. Typically, the very finely divided tobacco particles or pieces can be sized to pass through a screen of about 18 Tyler mesh, generally can be sized to pass a screen of about 20 Tyler mesh, often can be sized to pass through a screen of about 50 Tyler mesh, frequently can be sized to pass through a screen of about 60 Tyler mesh, may even be sized to pass through a screen of 100 Tyler mesh, and further may be sized so as to pass through a screen of 200 Tyler mesh. If desired, air classification equipment may be used to ensure that small sized tobacco particles of the desired sizes, or range of sizes, may be collected. In one embodiment, the tobacco material is in particulate form sized to pass through an 18 Tyler mesh, but not through a 60 Tyler mesh. If desired, differently sized pieces of granulated tobacco may be mixed together. In some products or formulations, very finely divided tobacco particles or pieces have a particle size greater than −8 Tyler mesh, often −8 to +100 Tyler mesh, frequently −18 to +60 Tyler mesh. In other products or formulations, very finely divided tobacco particles or powders suitable for smokeless products described herein can have a particle size less than −8 Tyler mesh, often +100 to +250 Tyler mesh, and frequently +120 to +280 Tyler mesh.

Tobacco extracts may be used as components of the tobacco product. A tobacco extract can be used in solid form (e.g., spray-dried or freeze-dried form), in liquid form, in semi-solid form, or the like. Exemplary tobacco extracts and extraction techniques are set forth, for example, in U.S. Pat. Nos. 4,150,677 to Osborne, Jr. et al.; 4,967,771 to Fagg et al.; 5,005,593 to Fagg et al.; 5,148,819 to Fagg; and 5,435,325 to Clapp et al., all of which are incorporated by reference herein. Various tobacco extraction and reconstitution methodologies are set forth in U.S. Pat. Nos. 5,065,775 to Fagg; 5,360,022 to Newton; and 5,131,414 to Fagg, all of which are incorporated by reference herein. See also, the tobacco extract treatment methodologies set forth in U.S. Pat. Nos. 5,131,415 to Munoz et al. and 5,318,050 to Gonzalez-Parra, both of which are incorporated by reference herein.

The tobacco materials that are processed optionally can incorporate reconstituted tobaccos, and as such, tobacco formulations that are processed can be absent of reconstituted tobacco ingredient components. However, suitable known reconstituted tobacco processing techniques, such as paper-making techniques or casting-type processes, can be employed to provide such optional tobacco ingredient components. See, for example, the types of paper-making processes set forth in U.S. Pat. Nos. 3,398,754 to Tughan; 3,847,164 to Mattina; 4,131,117 to Kite; 4,270,552 to Jenkins; 4,308,877 to Mattina; 4,341,228 to Keritsis; 4,421,126 to Gellatly; 4,706,692 to Gellatly; 4,962,774 to Thomasson; 4,941,484 to Clapp; 4,987,906 to Young; 5,056,537 to Brown; 5,143,097 to Sohn; 5,159,942 to Brinkley et al.; 5,325,877 to Young; 5,445,169 to Brinkley; 5,501,237 to Young; 5,533,530 to Young; which are incorporated herein by reference. See, for example, the casting processes set forth in U.S. Pat. Nos. 3,353,541 to Hind; 3,399,454 to Hind; 3,483,874 to Hind; 3,760,815 to Deszyck; 4,674,519 to Keritsis; 4,972,854 to Kiernan; 5,023,354 to Hickle; 5,099,864 to Young; 5,101,839 to Jakob; 5,203,354 to Hickle; 5,327,917 to Lekwauwa; 5,339,838 to Young; 5,598,868 to Jakob; 5,715,844 to Young; 5,724,998 to Gellatly; and 6,216,706 to Kumar; and EPO 565360; EPO 1055375 and PCT WO 98/01233; which are incorporated herein by reference.

If desired, prior to preparation of the tobacco product, the parts or pieces of tobacco material may be irradiated, or those parts and pieces may be pasteurized, or otherwise subjected to controlled heat treatment. Additionally, if desired, after preparation of all or a portion of a tobacco formulation, the component materials may be irradiated, or those component materials may be pasteurized, or otherwise subjected to controlled heat treatment. For example, a formulation may be prepared, followed by irradiation or pasteurization, and then flavoring ingredients and other additional components may be incorporated within the formulation. Alternatively, the tobacco product can be irradiated or pasteurized after the tobacco formulation has been processed (e.g., after an extruded tobacco product is formed, or after extruded product is sub-divided into a desired size and incorporated within a moisture-permeable packet or pouch so as to provide individual containers of snus-type smokeless tobacco product).

The tobacco materials also can be subject to other types of pre-treatment conditions prior to being used in the process steps of the present invention. For example, the tobacco materials can be treated to alter the physical or sensory characteristics of the of the tobacco material. In one regard, the tobacco material can be moistened or reordered. In another regard, the tobacco material can be pre-treated by treatment involving the application of heat, steam, cooking, or the like. In another regard, various additional components, such as those of the type set forth hereinafter, can be combined with the tobacco material during pre-treatment processing conditions (e.g., such as conditions involving heat treatment). In yet another regard, the tobacco material can be subjected to treatment processes involving the use of materials having acidic or basic characteristics. In still another regard, the tobacco material can be treated in the manner set forth in U.S. patent application Ser. No. 12/476,621, filed Jun. 2, 2009 to Chen et al.; each of which is incorporated herein by reference.

The tobacco materials that are processed can be processed in combination with at least one additional component. For example, the tobacco used for the manufacture of the tobacco product also can be processed, blended, formulated, combined and mixed with other materials or ingredients. For example, the tobacco composition can incorporate salts, sweeteners, binders, colorants, pH adjusters, buffering agents, fillers, flavoring agents, disintegration aids, antioxidants, humectants, and preservatives. See, for example, those representative components, combination of components, relative amounts of those components and ingredients relative to tobacco, and manners and methods for employing those components, set forth U.S. Pat. No. 5,387,416 to White et al.; U.S. Pat. App. Pub. Nos. 2005/0244521 to Strickland et al.; 2008/0029110 to Dube et al.; 2009/0293889 to Kumar et al.; U.S. patent application Ser. No. 12/476,621, filed Jun. 2, 2009 to Chen et al.; and PCT WO 05/041699 to Quinter et al., each of which is incorporated herein by reference.

The sensory attributes of smokeless tobacco can also be enhanced by incorporation of certain flavoring materials. Exemplary flavoring agents or flavorants that can be used are components, or suitable combinations of those components, that act to alter the bitterness, sweetness, sourness, or saltiness of the smokeless tobacco product, enhance the perceived dryness or moistness of the formulation, or the degree of tobacco taste exhibited by the formulation. Types of flavoring agents include salts (e.g., sodium chloride, potassium chloride, sodium citrate, potassium citrate, sodium acetate, potassium acetate, and the like), natural sweeteners (e.g., fructose, sucrose, glucose, maltose, mannose, galactose, lactose, and the like), artificial sweeteners (e.g., sucralose, saccharin, aspartame, acesulfame K, neotame, and the like); and mixtures thereof. Flavoring agents may be natural or synthetic, and the character of these flavors imparted thereby may be described, without limitation, as fresh, sweet, herbal, confectionary, floral, fruity or spice. Specific types of flavors include, but are not limited to, vanilla, coffee, chocolate/cocoa, cream, mint, spearmint, menthol, peppermint, wintergreen, eucalyptus, lavender, cardamon, nutmeg, cinnamon, clove, cascarilla, sandalwood, honey, jasmine, ginger, anise, sage, licorice, lemon, orange, apple, peach, lime, cherry, strawberry, and any combinations thereof. See also, for example, Leffingwell et al., Tobacco Flavoring for Smoking Products, R. J. Reynolds Tobacco Company (1972), U.S. Pat. Appl. Pub. Nos. 2002/0162562 to Williams; 2002/0162563 to Williams; 2003/0070687 to Atchley et al.; 2004/0020503 to Williams, 2005/0178398 to Breslin et al.; 2006/0191548 to Strickland et al.; 2007/0062549 to Holton, Jr. et al.; 2007/0186941 to Holton, Jr. et al.; 2007/0186942 to Strickland et al.; 2008/0029110 to Dube et al.; 2008/0029116 to Robinson et al.; 2008/0029117 to Mua et al.; 2008/0173317 to Robinson et al.; and 2008/0209586 to Neilsen et al., each of which is incorporated herein by reference. The amount of flavoring agents utilized within the tobacco product can vary, but is typically up to about 10 dry weight percent, and certain embodiments are characterized by a total flavoring agent content of at least about 1 dry weight percent, such as about 1 to about 10 dry weight percent. Combinations of flavorants are often may be used (e.g., about 0.1 to about 2 dry weight percent of an artificial sweetener and about 0.5 to about 8 dry weight percent of sodium chloride, based on the total dry weight of the tobacco product).

Exemplary filler materials include vegetable fiber materials such as sugar beet fiber materials (e.g., FIBREX® brand filler available from International Fiber Corporation), oats or other cereal grain (including processed or puffed grains), bran fibers, starch, or other modified or natural cellulosic materials such as microcrystalline cellulose. Additional specific examples include corn starch, maltodextrin, dextrose, calcium carbonate, calcium phosphate, lactose, manitol, xylitol, and sorbitol. An example of a commercially available maltrodextrin that can be used is Maltrin 10 DE available from Corn Products International. The amount of filler utilized in the tobacco composition or formulation can vary, but can be typically up to about 60 dry weight percent, and certain embodiments are characterized by a filler content of at least about 10 dry weight percent, such as about 20 to about 50 dry weight percent. Combinations of fillers may be used (e.g., a mixture composed of about 2 to about 8 dry weight percent of calcium carbonate, about 10 to about 20 dry weight percent of rice flour, and about 10 to about 20 dry weight percent of maltodextrin, based on the total dry weight of the tobacco product).

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

Exemplary colorants include various dyes and pigments. For example, suitable colorants can include caramel coloring, titanium dioxide, beta carotene, blackcurrant, annatto, grape skin, canthaxanthin, carrot powders or extracts, or the like. The amount of colorant utilized in the tobacco formulation can vary, but is typically at least about 0.1 dry weight percent, but up to about 5 dry weight percent, based on the total dry weight of the tobacco product. An exemplary amount of colorant is about 0.5 to about 3 dry weight percent, based on the total weight of the tobacco product.

Other ingredients such as preservatives (e.g., potassium or sodium sorbate, benzoate, propionate, sulfites, diacetate, parabens, and menthol), disintegration aids (e.g., microcrystalline cellulose, croscarmellose sodium, crospovidone, sodium starch glycolate, pregelatinized corn starch, and the like), or anti-sticking agents (e.g., exemplary commercially available product of Confecto™ No-Stick ‘N’™ sold by International Foodcraft Corporation) can also be used. Typically, such ingredients individually are used in amounts of up to about 10 dry weight percent, and usually at least about 0.1 dry weight percent, such as about 0.5 to about 10 dry weight percent, based on the total dry weight of the tobacco product.

The tobacco product incorporates a binder system, and the binder system incorporates at least one type of binding agent that exhibits thermoplastic properties, characteristics, or behaviors (e.g., the binding agent can be composed of at least one thermoplastic polymeric material). As such, a thermoplastic binder system can incorporate ingredients or materials so as to provide a binding agent that exhibits thermoplastic characteristics (e.g., the binding agent can be composed of at least one thermoplastic polymeric material and/or at least one thermoplastic binding material in combination with a plasticizing agent). The amount of thermoplastic binder system material employed within a representative processed tobacco product typically is at least about 5 percent, and often at least about 10 percent, of the final formed product, on a dry weight basis. The amount of thermoplastic binder system material employed within a representative processed tobacco product generally is less than about 40 percent, frequently is less than about 35 percent, often less than about 30 percent, and sometimes less than about 25 percent of the final formed product, on a dry weight basis.

The ingredient materials of the thermoplastic binder system can vary. The term thermoplastic as used herein refers to a property of an ingredient (e.g., a polymeric material) where upon heating, the ingredient softens or melts into a liquid that when cooled, hardens or forms a gel. For example, a polymeric material that comprises thermoplastic properties, characteristics or behaviors softens or melts when exposed to heat, and then returns to its original physical type of condition when cooled (e.g., to about ambient temperature). As such, a thermoplastic binding agent can be contacted with a tobacco material and various other ingredients, mixed so as to provide physical contact of the binding agent with those ingredients, heated so as to soften or liquefy the polymeric material of the thermoplastic binder system, and then cooled so as to harden the softened thermoplastic polymeric material (and hence result in a tobacco product that is formed from the ingredients and that has a desirable physical integrity). For purposes of the present invention, desirable thermoplastic polymeric materials generally soften or melt (and hence exhibit thermoplastic characteristics) at temperatures in excess of about 50° C., often in excess of about 60° C., and frequently in excess of about 70° C.

Examples of representative suitable thermoplastic polymeric materials include hydroxypropyl cellulose, polyethylene oxide, certain cellulose ethers (e.g. ethylcellulose and hydroxypropyl methylcellulose), polyvinyl alcohol and polyvinyl acetate. Examples of commercially available hydroxypropyl cellulose include KLUCEL® EF, ELF, and LF hydroxypropyl cellulose (HPC) sold by Hercules Incorporated, Aqualon Division. Examples of commercially available polyethylene oxide include Polyox N10 sold by The Dow Chemical Company. Examples of commercially available ethylcellulose include those available from Ronas Chemicals Ind. Examples of commercially available hydroxypropyl methylcellulose that can be used include Methocel™ E 50 sold by Hercules Incorporated, Aqualon Division. Examples of commercially available polyvinyl alcohol include Elvanol sold by E.I. DuPont de Nemours. Examples of commercially available polyvinyl acetate include Elvacet sold by E.I. DuPont de Nemours. See also, for example, the types of thermoplastic polymers, such as polymethyl acrylate, set forth in U.S. Patent Publication No. 2009/0095313 to Fuisz, which is incorporated by reference. Typical thermoplastic polymeric materials exhibit thermoplastic characteristics at temperatures below about 140° C., and more preferably below about 120° C. Highly preferred thermoplastic polymeric materials exhibit thermoplastic characteristics at temperatures below about 100° C., and most preferably below about 90° C.

The amount of thermoplastic polymeric materials employed within a representative processed tobacco product typically is at least about 5 percent, and often at least about 10 percent, of the final formed product, on a dry weight basis. The amount of thermoplastic polymeric material employed within a representative processed tobacco product generally is less than about 30 percent, frequently is less than about 25 percent, typically less than about 20 percent, and often less than about 15 percent of the final formed product, on a dry weight basis.

The binder system can incorporate a compound that can be characterized as a plasticizer. For example, the aforementioned thermoplastic binding materials can be combined with, and processing in the combination with, at least one plasticizer. Highly preferred plasticizers are organic non-polymeric materials, and exemplary representative plasticizers include glycerin, propylene glycol, polyethylene glycol, and combinations thereof. Certain plasticizers can be provided by various polyols, such as medium and high molecular weight polyol-type compounds. The amount of plasticizer utilized within the tobacco product can vary. When employed, the amount of plasticizer employed within a representative processed tobacco product typically is at least about 1 percent, often at least about 2 percent, and frequently at least about 3 percent, of the final formed product, on a dry weight basis. When employed, the amount of plasticizer employed within a representative processed tobacco product typically is up to about 15 percent, often up to about 10 percent, and frequently up to about 5 percent, of the final formed product, on a dry weight basis.

Typically, the selection and amount of plasticizer are such that there is provided a lowering in the softening temperature of the thermoplastic binding material. The plasticizer can act to facilitate hydration, and hence facilitate liquification of thermoplastic binding material. As such, formation of the tobacco product at relatively low temperatures can be facilitated. In this way, the binder system within a tobacco formulation can lower the operating temperature at which the tobacco formulation is formed thereby reducing and/or avoiding the scalding and/or charring of the tobacco materials. In addition, the plasticizer reduces the need for large amounts of moisture, or other liquid carrier materials, that in turn need to be boiled off through drying stages after formation of the tobacco product. For example, for tobacco formulations incorporating thermoplastic binding material, liquid (e.g., water) and plasticizer, there can be provided a formulation suitable for extrusion of a desirable tobacco product, at temperatures typically lower than that of the normal melting point of the thermoplastic binding material.

Highly preferred thermoplastic binding materials that can be suitably employed in combination with at least one plasticizer can vary. Examples of such types representative thermoplastic binding materials include polyvinyl polypyrrolidone, methylcellulose, xanthan, gum arabic, maltodextrin, pullulan, certain modified starches and high molecular weight propylene glycols (e.g., propylene glycols having molecular weights above about 4000). Examples of commercially available polyvinyl polypyrrolidone that can be used include Plasdone® K-29/32 sold by FMC BioPolymer. Examples of commercially available methylcellulose that can be used include the Methocel Series of polymeric materials sold by Hercules Inc., Aqualon Division. Examples of commercially available xanthan and gum arabic that can be used include those available from TIC Gums. Examples of commercially available maltodextrin that can be used include Maltrin 10 DE available from Grain Processing Corp. Examples of suitable commercially available modified starches include Elastigel™ 1000J and INSTANT TEXTAID®-A sold by National Starch and Chemical Company. Examples of suitable high molecular weight propylene glycol that can be used include PEG 4000 sold by The Dow Chemical Company. Suitable pullulan materials are set forth in US Pat. Appl. Pub. No. 2007/0246055 to Borschke, et al., which is incorporated herein by reference. When employed in conjunction with effective amounts of plasticizer, such types of thermoplastic binding materials typically exhibit thermoplastic characteristics at temperatures below about 140° C., and more preferably below about 120° C. Highly preferred thermoplastic binding materials exhibit thermoplastic characteristics at temperatures below about 100° C. These types of thermoplastic binding materials that can be suitably employed in combination with the aforementioned plasticizer can be employed with thermoplastic polymeric materials, and in some cases in the absence of a plasticizer.

The amount of thermoplastic binding materials employed within a representative processed tobacco product typically can be at least about 5 percent, and often at least about 10 percent, of the final formed product, on a dry weight basis. The amount of thermoplastic binding material employed within a representative processed tobacco product generally can be less than about 30 percent, frequently is less than about 25 percent, typically less than about 20 percent, and often less than about 15 percent of the final formed product, on a dry weight basis.

Thermoplastic polymeric materials, thermoplastic binding materials employed in combination with a plasticizer, and mixtures of these materials can be processed at the processing and operating conditions of the present invention described herein. Such thermoplastic polymeric materials, thermoplastic binding materials employed in combination with a plasticizer, and mixtures of these materials typically exhibit thermoplastic characteristics at temperatures below about 140° C., and more preferably below about 120° C. Highly preferred thermoplastic polymeric materials, thermoplastic binding materials employed in combination with a plasticizer, and mixtures of these materials employed in combination with a plasticizer exhibit thermoplastic characteristics at temperatures below about 100° C.

The thermoplastic binder systems can be employed in conjunction with other binding agents. Typical of such other types of binding agents are those that include, but are not limited to, carboxymethyl cellulose and certain other modified cellulosic materials, alginates such as sodium alginate, certain starch-based binders, pectins, carrageenan, zein, and the like. These types of binding agents may not substantially exhibit thermoplastic behavior or characteristics under the conditions and processes of the present invention. One exemplary carboxymethyl cellulose is commercially available as Ac-Di-Sol® sold by FMC BioPolymer. Examples of suitable alginates that include Algin 400 sold by TIC Gums and the Manucol types alginates sold by FMC Biopolymers. Examples of suitable starch-based binders include pre-gelatinized rice starches. Examples of suitable pectins and carrageenans are available from TIC Gums and FMC Biopolymers. Examples of suitable zein that are available from Alfa Chemicals. The amount of the other optional binding agent employed typically is less than about 20 percent, and often less than about 15 percent, and frequently is less than about 10 percent, of the final formed product, on a dry weight basis. When employed, the amount of the other optional binding agent that employed typically is at least about 1 percent, and often at least about 3 percent, and frequently at least about 5 percent, of the final formed product, on a dry weight basis. In certain systems, these optional binding agents may require additional moisture when employed in a tobacco product.

The manner by which the various components of the tobacco formulation can be combined may vary. The various components of the formulation may be contacted, combined, or mixed together in conical-type blenders, mixing drums, ribbon blenders, or the like. As such, the overall mixture of various components with the granulated tobacco components, and other ingredients, may be relatively uniform in nature. See also, for example, the types of methodologies set forth in U.S. Pat. No. 4,148,325 to Solomon et al.; U.S. Pat. No. 6,510,855 to Korte et al.; and U.S. Pat. No. 6,834,654 to Williams, each of which is incorporated herein by reference. The components of the tobacco formulation can be brought together in admixture using any mixing technique or equipment known in the art. The components noted herein, which may be in liquid or dry solid form, can be admixed with the tobacco in a pretreatment step prior to mixture with any remaining components of the composition or simply mixed with the tobacco together with all other liquid or dry ingredients. Any mixing method that brings the tobacco composition ingredients into intimate contact can be used. A mixing apparatus featuring an impeller or other structure capable of agitation is typically used. Exemplary mixing equipment includes casing drums, conditioning cylinders or drums, liquid spray apparatus, ribbon blenders, mixers available as FKM130, FKM600, FKM1200, FKM2000 and FKM3000 from Littleford Day, Inc., Plough Share types of mixer cylinders, and the like.

Components of the tobacco formulation also can be provided by liquid materials or ingredients. The liquid ingredients can be provided in a variety of ways, and can be provided from a variety of sources. The tobacco formulation can be moist, and moisture can be provided by aqueous liquid supplied as such, as moist tobacco, or as a carrier liquid for ingredients of the tobacco formulation. Other liquid ingredients, such as organic solvents (e.g., ethanol), can be carrier liquids for certain ingredients of the tobacco formulation. The plasticizers of the thermoplastic binder system also typically have a liquid form.

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

The manner that the tobacco product is formed can vary, and various methods for forming processed tobaccos or for producing processed tobacco products will be readily apparent to those skilled in the art of tobacco product manufacture. For example, suitably heated tobacco formulations incorporating thermoplastic binder systems and having a pourable, formable or generally liquid character can be cast into a sheet-like form and cooled to yield a sheet-like tobacco product of good integrity. As another example, suitably heated tobacco formulations incorporating thermoplastic binder systems can be molded into a desired shape and cooled. As yet another, but preferred, example, tobacco formulations incorporating thermoplastic binder systems can be extruded from heated extrusion devices and cooled.

The tobacco product can be manufactured using hot melt extrusion techniques. As such, processed tobacco formulations can be subjected to sufficient heat during formation of tobacco product to eliminate the need for any additional heat treatment steps. For example, flashing off the moisture from a processed tobacco formulation during a hot melt extrusion process can eliminate any need for further heating, drying, or the like.

Processed tobacco formulations, such as multi-layered tobacco pellets, can be manufactured using a wide variety of extrusion techniques. For example, multi-layered tobacco pellets can be manufactured using co-extrusion techniques (e.g., using twin screw extruders). In such a situation, successive wet or dry components or component mixtures can be placed within separate extrusion hoppers. Steam, gases (e.g., ammonia, air, carbon dioxide, and the like), and plasticizers (e.g., glycerin or propylene glycol) can be injected into the extruder barrel as each dry mix is propelled, plasticized, and cooked. As such, the various components are processed so as to be very well mixed, and hence, come in complete contact with each other. For example, the contact of components is such that individual components can be well embedded in the extrusion matrix or extrudate. See, for example, U.S. Pat. No. 4,821,749 to Toft et al., which is incorporated herein by reference. Multilayered materials can have the general form of films, and alternatively, multi-layered generally spherical materials can possess various layers extending from the inside outward.

Some shapes of smokeless tobacco products, such as rods or cubes, can be formed by first extruding the material through a die having the desired cross-section (e.g., round or square) and then optionally cutting the extruded material into desired lengths. For example, extruder equipment comprising single or multiple screw extruders can by employed to form the shape of a smokeless tobacco product. Some extruders can comprise twin screw extruders which comprise co-rotating twin screw extruders. Various screw configurations can be employed. For example, screws having combinations of elements for feeding, mixing, pumping, shearing, and the like, can be selected as desired for optimum results. Screws having sections or elements which provide relatively large output capacities, which have interrupted or nonconjugated flights, or which are “counterflighted” or “reversing” also can be employed. Typical screw elements as well as screws having combinations of such elements are available from extruder manufacturers. An extruder can provide a barrel for heating of the materials which are introduced within the extruder. The conditions of the extrusion set-up can vary, for example, in modifying feed rate of dry blend ingredients, feed rate of wet blend ingredients, screw RPM setting, temperature conditions, aperture die dimensions, as well as additional parameters.

Techniques and equipment for extruding tobacco materials have been set forth in U.S. Pat. Nos. 3,098,492 to Wursburg; 4,874,000 to Tamol et al.; 4,880,018 to Graves et al.; 4,989,620 to Keritsis et al.; 5,072,744 to Luke et al.; 5,829,453 to White et al.; and 6,182,670 to White et al.; each of which is incorporated herein by reference. Exemplary extrusion equipment suitable for use include industrial pasta extruders such as Model TP 200/300 available from Emiliomiti, LLC of Italy.

Processed sheet-like materials can be prepared by applying the tobacco composition onto a moving belt and passing the moving belt through a nip formed by opposing rollers, followed by cutting the sheet into desired lengths. Alternatively, the tobacco product can be over-coated with powdered or liquid coating. Furthermore, if desired, the surface of the tobacco product can be embossed or printed.

The pH of the tobacco product can vary. Typically, the pH of that formulation is at least about 6.5, and preferably at least about 7.5. Typically, the pH of the tobacco product will not exceed about 10, and often will not exceed about 9.5. A representative tobacco product exhibits a pH of about 6.8 to about 8.2. A representative technique for determining the pH of a tobacco product involves dispersing 5 g of that product in 100 mL of deionized water, and measuring the pH of the resulting suspension/solution (e.g., with a pH meter).

The relative amount of tobacco employed in combination with the additional components and binding system components can vary. The amount of tobacco material within the tobacco product typically is at least about 10 percent, generally at least about 25 percent, often at least about 30 percent, and frequently at least about 35 percent, on a dry weight basis, based on the total dry weight of the processed formulation or final product. In certain instances, the amounts of other components and binding system components within the tobacco formulation may exceed about 40 percent, on a dry weight basis. A typical range of tobacco material within the formulation is about 10 to about 60 weight percent, more often about 20 to about 40 weight percent, on a dry basis.

The moisture content of the tobacco product prior to use by a consumer of the product may vary. Typically, the moisture content of the tobacco product, such as tobacco formulation within a snus-type pouch, prior to insertion into the mouth of the user, is less than about 55 weight percent, generally is less than about 50 weight percent, and often is less than about 45 weight percent. Certain types of tobacco products have moisture contents, prior to use, of less than about 15 weight percent, frequently less than about 10 weight percent, and often less than about 5 weight percent. A tobacco product can comprise a moisture content prior to use in the range of about 5 weight percent to about 15 weight percent. For certain tobacco products, such as those incorporating snus-types of tobacco compositions, the moisture content may exceed 20 weight percent, and often may exceed 30 weight percent. For example, a representative snus-type product may possess a tobacco composition exhibiting a moisture content of about 25 weight percent to about 50 weight percent, preferably about 30 weight percent to about 40 weight percent. For yet other tobacco products, such as those in a stick form, the tobacco product can comprise a moisture content of about 5 weight percent to about 15 weight percent.

Exemplary shapes of formed tobacco products include pill, tablet, sphere, sheet, film, coin, cube, bead, ovoid, obloid, bean, stick, and rod. Tobacco products of the present invention can be used as smokeless tobacco compositions, such as loose moist snuff, loose dry snuff, chewing tobacco, pelletized tobacco pieces, compressed tobacco pieces, molded processed tobacco pieces, extruded or formed tobacco strips, pieces, rods or sticks, finely divided ground powders, finely divided or milled agglomerates of powdered pieces and components, flake-like pieces, pieces of tobacco-containing gum, rolls of tape-like films, readily water-dissolvable or water-dispersible films or strips (see, for example, U.S. Pat. Appl. Pub. No. 2006/0198873 to Chan et al. and U.S. Pat. Appl. Pub. No. 2009/0095313 to Fuisz), extruded or formed sticks or rods, extruded or molded tubes, layered or laminated materials (e.g., multi-layered compositions having one type of tobacco formulation surrounded by a different type of tobacco formulation), or capsule-like materials possessing an outer shell (e.g., a pliable or hard outer shell that can be clear, colorless, translucent or highly colored in nature) and an inner region possessing tobacco or tobacco flavor (e.g., a Newtonian fluid or a thixotropic fluid incorporating tobacco of some form). As an example, pieces of extruded sheets or films can be wrapped around formed tobacco-containing pieces. As yet another example, extruded pieces can be sub-divided into small pieces and incorporated with other tobacco materials within snu-type pouches. A preferred form of a tobacco product is a product having the form of an extruded piece or pieces composed of tobacco material and other ingredients held together using a binder system. Such extruded pieces also may be processed or further sub-divided into formed pieces. For example, extruded tobacco compositions can be roll pressed or otherwise physically treated; and then rolled into a roll for storage and later use, or cut into the desired shape for packaging and use.

Tobacco products incorporating thermoplastic binder systems offer several advantages. In one regard, the binder system allows for efficient and effective extrusion of a tobacco product (e.g., tobacco product can be produced at a desired throughput). In another regard, extrusion of a tobacco formulation can be carried out at relatively low temperatures; and as such the tobacco formulation can be processed using reduced amounts of energy and under conditions that reduce the chances of scalding or charring the tobacco material during processing. In yet another regard, tobacco products possessing reduced amounts of binding agent can be provided, hence increasing the relative amount of tobacco and flavoring agent within the tobacco product and thereby enhancing the sensory characteristics of those products.

The incorporation of the binder system into a tobacco product according to methods described herein can provide improved user satisfaction upon use of the tobacco product as compared to a tobacco product relying upon a thermoplastic polymer in relatively high concentrations. In tobacco formulations comprising high concentrations of thermoplastic polymers, some users may experience a “gummy residue” in their mouth upon use of the tobacco product.

The present invention can be more fully illustrated by the following examples, which are set forth to illustrate some embodiments of the present invention and are not to be construed as limiting thereof. All weight percentages are expressed on a dry weight basis, meaning water content is excluded, unless otherwise indicated.

A tobacco formulation for use as a stick type of a smokeless tobacco product is provided in the manner set forth in Table 1. The smokeless tobacco product comprising the tobacco formulation of Table 1 can be used as a control formulation as compared to the additional examples of the present invention that are set forth and described hereinafter.

The tobacco powder used in Example 1 is a blend of finely divided (−100/+270 Tyler mesh) flue-cured tobacco lamina and air cured tobacco stems. All dry ingredients, in powder form, as well glycerin and propylene glycol, are added together and thoroughly mixed in a model 300D Littleford horizontal plough dough mixer (Littleford Day, Inc. Florence, Ky.) for about 15 to 20 minutes at about 150 rpm. The mixed dry formulation is then commuted into the hopper of a model ZSK26 Coperion extruder (Werner and Pfeidderer, Ramsey, N.J.). The extruder barrel has a 30:1 LD (length to diameter) ratio, 26 inch internal diameter, and consists of 8 heating zones or sections, plus a heated die component.

The extruder is set at a screw speed of about 45 rpm and the barrel sections and die operated at temperatures of about 100° C. The extruder is fed at a rate of about 10.5 lb/hr of dry formulation from a hopper. The formulation is extruded through a 3.0 mm diameter aperture die into 3 mm diameter cylindrical rods. Residence time of the formulation in the extruder is approximately 55 seconds. The rods are cut into approximately 61 centimeter long sticks, and allowed to harden by ambient air drying for about 10 to 20 minutes, after which the sticks are further cut into 3.5 mm long pieces.

TABLE 1 Ingredients wt % g Tobacco Powder 36 360 Mannitol 13 180 Sodium chloride 3.6 36 Sodium hydroxide 0.4 4 Sucralose 1 10 Titanium dioxide 1 10 Calcium Carbonate 3 30 Maltodextrin 3 30 Ac-Di-Sol ® 3 30 Glycerin 0.8 8 Cocoa Powder 2 20 Licorice Powder 0.5 5 Vanilla 0.2 2 Hydroxypropyl 28.5 285 Cellulose Propylene Glycol 4 40 Total ingredients: 100% 1000.0

Tables A-J provide various embodiments of a binder system that can be incorporated into a tobacco formulation for use in a tobacco product representative of the present invention. The binder system prepared according to the recipes shown in Tables A-J can be used within the tobacco formulations found in the examples described hereinafter.

Each batch of binder system is prepared by mixing the components in a commercially available Kitchen Aid mixer for about 3 to 5 minutes.

TABLE A Batch 1 Ingredients wt % g

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