Abstract: A substantially cylindrical foamed, extruded, tobacco-containing smoking article is provided which has properties substantially equivalent to those of a conventional cigarette and which contains from about 5 to about 98 wt. % of tobacco particles having a particle size of up to about 5 mesh, from 0 to about 60 wt. % of a filler having a particle size of up to about 350 .mu.m mesh, from about 2 to about 40 wt. % of a cellulosic binder selected from the group consisting of hydroxypropyl cellulose, carboxymethyl cellulose, and its sodium, potassium and ammonium salts, cross-linked carboxymethyl cellulose, and its sodium, potassium and ammonium salts, hydroxyethyl cellulose, ethyl hydroxyethyl cellulose, hydroxypropyl methyl cellulose, methyl cellulose, ethyl cellulose, and mixtures thereof, and from about 5 to about 20 wt. % water. The article has a density within the range of from about 0.05 to about 1.5 g/cc.

Abstract: A process for producing a synthetic smoking material is disclosed. The process preferably comprises forming an aqueous slurry of cellulosic material, preferably in the form of loose and slightly beaten cellulose fibers, adding certain metal salts to the slurry, casting the same and thereafter drying, conditioning and slitting or cutting the resulting sheet to produce a low tar filler material. The water-soluble metal salts to be added are selected from the group consisting of calcium salts, magnesium salts, iron salts, and aluminum salts, and are preceded or followed by addition of ammonium or alkali metal salts capable of precipitating the cation of the said water-soluble salts.

Abstract: The present invention provides a method according to which a cellulose rod, at least 11 mm in diameter and formed from cellulosic paper made by the wet paper-making process, that has been treated with a binding agent, repeatedly folded along its longitudinal axis and passed through a heated forming die to provide a coherent rod, is treated with an additive and then pyrolyzed by being advanced through a die maintained at a temperature within the range of from about 500.degree. C. to about 1000.degree. C. in an oxygen-free atmosphere for a total retention time in the die of from about 3 seconds to about 1 minute. The pyrolyzed cellulose rod is then cooled to less than about 250.degree. C. before being removed from the oxygen-free atmosphere. The resulting combustible carbonized rod may be cut to suitable lengths and employed as a filter in tobacco-containing cigarettes or may be used to form a tobacco-free cigarette.

Abstract: A process is disclosed for increasing the filling power of tobacco lamina filler having an OV value, immediately before treatment, within the range of from about 1% to about 10%, preferably from about 2% to about 7%, without the use of exogenous impregnants by contacting the filler with a high velocity gaseous medium at elevated temperature such that heat is rapidly and substantially uniformly transferred from the medium to the filler for a total contact time sufficient to stiffen and expand the filler.

Abstract: A process for selectively denitrating tobacco by electrodialysis to thereby reduce the delivery of various gas phase components, during combustion of tobacco products is disclosed. The process comprises forming an aqueous tobacco extract, separating the extract from the fibrous tobacco portion, selectively denitrating the extract and reapplying the denitrated extract to a fibrous tobacco portion. Denitration of the extract is effected by circulating the extract through those cells of an electrodialysis unit having anion permeable membrane towards both anode and cathode, said extract cells being paired on their anode side with brine cells which have a cation permeable membrane toward the anode. The cell pairs are separated by cells through which an acid is circulated. Smoking products containing tobacco treated in accordance with the invention exhibit reduced delivery of nitrogen oxides during combustion.

Abstract: An artificial method of curing green tobacco is provided wherein the tobacco is exposed to sulfur dioxide gas. Curing can be effected by completely contacting the tobacco with sulfur dioxide gas and thereafter allowing the tobacco to brown until the desired color is achieved.

Abstract: A method for employing tobacco dust in a paper-making process for the preparation of reconstituted tobacco is disclosed. The method for employing the tobacco dust comprises admixing tobacco dust with a bonding material to form a mixture, treating the mixture to form agglomerated particles, admixing the agglomerated particles with a tobacco-parts slurry and then forming the slurry into a sheet by means of a paper-making process, drying and then shredding the resultant reconstituted tobacco sheet. The smoking material obtained by such method is also described.

Abstract: An improved smoking material affording reduced particulate matter and puff count yet having the flavor and aromatic qualities of natural tobacco, which comprises cellulosic material having incorporated therein a metal salt from the group consisting of calcium salts, magnesium salts, iron salts, and aluminum salts of various organic or inorganic acids. A process for producing such a synthetic smoking material is also disclosed. The process preferably comprises forming an aqueous slurry of the cellulosic material, preferably in the form of loose and slightly beaten cellulose fibers, adding the metal salt to the slurry, casting the same and thereafter drying, conditioning and slitting or cutting the resulting sheet to produce a low tar filler material. A preferred embodiment of the invention resides in foaming the slurry prior to casting the same to form an expanded product.

Abstract: A process for treating tobacco to reduce the delivery of various gas phase components, during combustion of tobacco products is disclosed. The process comprises contacting tobacco material with an aqueous solution to form a tobacco extract. After separating the extract from the fibrous tobacco portion, the extract is treated by an ionic extraction means such that nitrate ions are extracted while the potassium ion content of the extract is left substantially intact. The treated extract may then be recombined with the fibrous tobacco products. Such products exhibit reduced delivery of nitrogen oxides, HCN and CO during combustion.

Abstract: An improved process for denitrating tobacco with minimal losses of desirable tobacco solubles employing electrodialysis is disclosed. The process comprises subjecting an aqueous tobacco extract to membrane electrodialysis such that nitrate salts are extracted, without substantial loss of desirable tobacco solubles, while minimizing conflicting reactions in the electrodialysis unit and prolonging membrane life. Conflicting reactions are reduced and membrane life is enhanced by isolation of the electrodes to prevent electrolysis in the extract and brine by use of an anion permeable membrane adjacent the cathode and by use of a catholyte, the anion of which forms soluble salts with polyvalent cations. The denitrated extract when combined with denitrated insoluble fibrous tobacco materials may be employed to produce tobacco products having reduced nitrogen oxide delivery.

Abstract: A method for utilizing waste cellulosic material by conversion to sugars suitable for use in tobacco manufacturing is disclosed. The method comprises comminuting waste cellulose products, which are generated during tobacco product manufacturing, deesterifying any waste cellulose acetate present in the waste products, enzymatically saccharifying the deesterified and comminuted products to simple sugars and recovering the sugars produced. The recovered sugars may be utilized in tobacco treatment processes. Enzymatic saccharification is preferably effected with Trichoderma viride cellulases.

Abstract: A method of producing a smokable material having reduced particulate matter, particularly tar, nicotine and puff count, while still maintaining the desirable characteristics of a smoking material is disclosed. The method comprises pyrolyzing a carbohydrate material to a weight loss of at least 10%, forming a slurry of tobacco-parts, adding the pyrolyzed carbohydrate material to the slurry, homogenizing the slurry and processing the resultant product to a form desired for the smoking material. The smokable material obtained by such method is also described.

Abstract: A method of producing a smokable material containing tobacco by-products, such as stems or stalks, having reduced particulate matter, particularly, tar and nicotine, and which additionally has no undesirable "woody taste" is disclosed. The method for producing this smokable material comprises subjecting tobacco by-products material to pyrolysis, adding the pyrolyzed material to a tobacco-parts slurry, homogenizing the slurry, drying and processing the resultant reconstituted product to a form desired for the smoking material. The smoking material obtained by such method is also described.

Abstract: A process for denitrating tobacco with minimal losses of desirable tobacco solubles employing electrodialysis is disclosed. The process comprises subjecting an aqueous tobacco extract to membrane electrodialysis such that nitrate salts are extracted, without substantial loss of desirable tobacco solubles. The denitrated extract when combined with denitrated insoluble fibrous tobacco materials may be employed to produce tobacco products having reduced nirogen oxide delivery.