Abstract: The present invention is directed to an encapsulated material for use in chewable compositions. The encapsulated material is formed by blending an encapsulating solution with essential oils or other hydrophobic or amphipathic compounds flavoring solution to form a homogenous coating solution. The homogenous coating solution is contacted with a substrate to provide a flavored composition.

Abstract: A leaf tobacco extract or a concentrate thereof is used as a dispersion medium, which is mixed with powder of a heat-irreversibly coagulating glucan and a dispersion interference-preventing agent including an organic acid. The resultant mixture is stirred to disperse the powder of glucan into the dispersion medium, thereby preparing a slurry having an increased viscosity. This slurry is formed into a sheet, which is then heated and coagulated.

Abstract: Sheet tobacco according to the present invention includes a carrier sheet made of nonwoven plant fibers, and a tobacco powder layer formed on the carrier sheet and containing a powder mixture of tobacco lamina powder and binder powder. In a sheet tobacco manufacturing process according to the present invention, a carrier sheet of plant fibers is formed by a nonwoven fabric production process, a tobacco powder layer is formed by spreading the powder mixture on the carrier sheet, and a cover sheet of plant fibers is optionally formed on the tobacco powder layer. Subsequently, the carrier sheet, the tobacco powder layer and the optical cover sheet are all together subjected to heating and pressing, thereby producing sheet tobacco with a two- or three-layer structure. The present invention also provides a manufacturing system for carrying out the sheet tobacco manufacturing process.

Abstract: An apparatus and method for drying reconstituted tobacco sheets includes positioning a steam box below an endless conveyor belt. A slurry is cast onto the conveyor belt and conveyed over a steam box before entry into a drying apparatus. The steam box functions to pre-treat the slurry so as to increase the rate by which the slurry may be dried. The steam box includes the use of a perforated plate which encloses an upper portion of the steam box and which functions to uniformly distribute steam to the underside of the conveyor belt.

Abstract: A low-density filler material for cigarettes from either a low-density tobacco composition or an extruded grain or starch composition. The low-density tobacco composition and a method of making the low-density tobacco composition by extruding a mixture of tobacco and flour or tobacco and starch under conditions whereby the solvent in the extruded mixture flashes into vapor upon release from the extrusion head. The low-density tobacco composition is formed without the aid of an added binder. The low-density flour or starch material and a method of making it by extruding flour or starch with a filler material such as calcium carbonate under conditions whereby the solvent in the extruded mixture flashes into vapor upon extrusion through the orifice die. The extruded composition can then be cut and used in place of cut tobacco filler.

Abstract: A tobacco flavor-tasting article is manufactured by preparing a heat-irreversibly coagulated glucan sheet containing a tobacco extract. The glucan sheet is prepared by preparing a sheet-like material from a high viscosity aqueous dispersion containing the extract obtained by an extraction treatment of a leaf tobacco, together with a heat-irreversibly coagulating glucan, and heating the sheet-like material to coagulate the glucan. This sheet is cut or pulverized to prepare a tobacco flavor-generating material. On the other hand, a tobacco flavor-adjusting material is prepared by preparing a sheet-like material from a leaf tobacco fibrous residue, which is the residue after the extraction, and cutting the sheet-like material. These tobacco flavor-generating material and tobacco flavor-adjusting material are used in combination to produce a cigarette-like article.

Abstract: A novel cigarette adapted for use in an electrical cigarette system comprising a tobacco rod having filled and unfilled tobacco rod portions and being arranged so that electrical heater elements may overlap the filled and unfilled tobacco rod portions. The tobacco rod includes a tobacco web rolled into tubular form. The tobacco web is constructed in accordance with a novel process comprising the steps of converting tobacco feedstock into a continuous sheet of tobacco web and converting the continuous sheet of tobacco web into one or more bobbins of tobacco web suitable for automated manufacture of cigarettes.

Abstract: A process to improve the smoke quality and mechanical properties of reconstituted tobacco is accomplished by adding tobacco materials to an aqueous solution containing ammonium salts and urea. The resulting first tobacco slurry is then pressurized under steam pressure to at least 60 psi for a period of from 1 to 5 minutes then depressurized rapidly to ambient. The depressurized tobacco is then formed into a second tobacco slurry wherein the soluble components within the tobacco is removed. The resulting tobacco residue is then prepared into a reconstituted tobacco sheet and the extract is then concentrated to a solids level of at least 30 percent by weight of solids which is added back to the reconstituted tobacco sheet for further processing into smoking articles.

Abstract: A process for improving smoke quality and mechanical properties of a cast reconstituted tobacco sheet is accomplished by adding tobacco materials to an aqueous solution containing ammonium salts and ammonium hydroxide. The resulting first tobacco slurry is then pressurized under steam pressure to at least 60 psi for a period of from about 1 to 5 minutes then depressurized rapidly to ambient. The depressurized tobacco is then formed into a second tobacco slurry. The resulting tobacco residue is then cast into a reconstituted tobacco sheet for further processing into smoking articles.

Abstract: A process for the manufacture of a reconstituted tobacco product wherein the process comprises extraction of tobacco furnish with an aqueous solvent in the presence of at least one ammonium salt or urea or a urea derivative or a mixture of urea or a urea derivative and at least one ammonium salt to provide an aqueous solvent extract and a fibrous material and forming the fibrous material into a sheet-like product using the papermaking process. The aqueous extract is then applied to the formed sheet-like material and further processing provides a reconstituted tobacco product having improved smoke quality.

Abstract: The process of the present invention involves extracting components from a tobacco material or other plant material using a solvent having an aqueous character to provide separately an aqueous tobacco extract and a water insoluble tobacco portion. The insoluble tobacco portion is refined and a slurry is produced. The slurry is formed into a predetermined shape, e.g., a formed web. The formed web can be pressed to reduce the moisture content. The tobacco material preferably has a moisture content of at least about 50 percent by weight. The material is contacted with an aqueous mixture of an aerosol precursor material. The ratio of liquid having an aqueous character to aerosol precursor material is typically from about 25 to 75 percent by weight. Immediately after the introduction of the aerosol precursor material, the web is dried at a preselected temperature so that the aerosol precursor material is dispersed evenly throughout the web.

Abstract: A real-time cast sheet weight monitoring and control system in which the weight of a cast base sheet of wet laid tobacco slurry as well as the weight of a composite tobacco cast sheet formed by applying dry granular tobacco to the wet laid cast sheet prior to drying is disclosed in which two beta gauge sheet weight sensing devices are used to provide input signals to a controller which alternately uses those signals to monitor and control the weight of the cast base sheet by means of controlling the servo drive motors of a casting blade in a head box which is casting the wet laid sheet onto a stainless steel belt and which also uses those same signals to control the variable speed drive of a top loader for controlling the amount of dry granular tobacco which is uniformally applied to the wet laid cast base sheet prior to the drying of the composite tobacco cast sheet material formed thereby.

Abstract: Reconstituted tobacco sheet having improved homogeneity and wet and dry tensile strength are produced by a process including mixing a water-soluble polysaccharide and a humectant under a first high shear; subjecting the resulting aqueous binder composition to a second high shear mixing operation; mixing the resulting aqueous binder composition with tobacco dust under a third shear, the third shear being lower than the first and second shears to form a slurry; casting the slurry onto a supportive surface such as a stainless steel conveyor belt; drying the cast slurry to form a reconstituted tobacco sheet; and recovering the reconstituted tobacco sheet for use such as cut filler for cigarettes.

Abstract: The process of the present invention involves extracting components from a tobacco material or other plant material using a solvent having an aqueous character to provide separately an aqueous tobacco extract and a water insoluble tobacco portion. The insoluble tobacco portion is refined and a slurry is produced. The slurry is formed into a predetermined shape, e.g., a formed web. The formed web can be pressed to reduce the moisture content. The tobacco material preferably has a moisture content of at least about 50 percent by weight. The material is contacted with an aqueous mixture of an aerosol precursor material. The ratio of liquid having an aqueous character to aerosol precursor material is typically from about 25 to 75 percent by weight. Immediately after the introduction of the aerosol precursor material, the web is dried at a preselected temperature so that the aerosol precursor material is dispersed evenly throughout the web.

Abstract: A process and sheet material made therefrom, for preparation of a sheet material intended for the manufacture of smoking products such as cigars, cigarettes, or similar products, in which aromatic substances or preparations intended not to be released until the moment of combustion of the smoking product and which are included by molecular encapsulation or complexing in cyclodextrins are introduced into the paste used to make the sheet, wherein measures are taken so that the said aromatic substances are all included in cyclodextrins.

Abstract: A process for the manufacture of a reconstituted tobacco product wherein the process comprises extraction of tobacco furnish with an aqueous solvent in the presence of at least one ammonium salt or urea or a urea derivative or a mixture of urea or a urea derivative and at least one ammonium salt to provide an aqueous solvent extract and a fibrous material and forming the fibrous material into a sheet-like product using the papermaking process. The aqueous extract is then applied to the formed sheet-like material and further processing provides a reconstituted tobacco product having improved smoke quality.

Abstract: This invention relates to methods of increasing the viscosity of a dispersion containing an alginate by subjecting the dispersion to high shear, such as the shear in a laboratory valve homogeniser. The viscosity of the dispersion increases within the range of two fold to five hundred fold.The method of increasing viscosity is useful in tobacco reconstitution or tobacco substitut processes, especially where either low levels of binder are required or improved taste characteristics over cellulosic binders, for example, are important.

Abstract: The present invention relates to a method for providing a reconstituted tobacco material. The method includes contacting tobacco material dispersed in a liquid having an aqueous character with a humectant or binding agent or both under high shear mixing conditions at a temperature of at least about 35.degree. C. to provide a mixture. The mixture is then contacted with a pectin release agent, preferably at a pH of about 5 to about 9, while maintaining the high shear mixing conditions to provide a tobacco material having released tobacco pectins. Preferably, the tobacco material having released tobacco pectins is then formed into a predetermined shape and subjected to conditions sufficient to cause the released tobacco pectins to undergo crosslinking.

Abstract: The invention relates to a process for collecting dispersed plant material particles during the formation of a reconstituted plant material, such as a reconstituted tobacco material. The process involves extracting components from a plant material using a solvent having an aqueous character. As such, an aqueous plant material extract and a water insoluble tobacco portion are provided. At least a portion of the aqueous extract is separated from the insoluble portion. The insoluble portion is formed into a desired shape (e.g., a sheet-like shape). Excess solvent is removed from the formed insoluble plant portion. The removed solvent has plant material particles dispersed therein and is collected. A portion of the excess solvent is removed from the dispersed plant material particles. The dispersed plant material particles are then collected.

Abstract: A tobacco-containing paper is provided using a reconstituted tobacco material as a component thereof. A reconstituted tobacco material, provided using papermaking techniques from a refined tobacco pulp, is refined into a pulp form and provided as a slurry in water. The slurry is combined with inorganic filler (e.g., calcium carbonate particles) and cellulosic pulp (e.g., wood pulp). The resulting slurry is then employed to provide a paper using papermaking techniques. The tobacco-containing paper has many desirable physical characteristics.

Abstract: An apparatus and method for manufacturing reconstituted tobacco sheet in which a tobacco containing slurry is metered on to the outer surface of a rotating heated cylindrical dryer and then, after sufficient drying, is removed from the cylindrical dryer.

Abstract: Smokable and/or combustible tobacco material is provided by altering the character of tobacco material.Tobacco material is extracted using a solvent to provide a tobacco extract within the solvent and an extracted tobacco material. The extracted tobacco material is separated from at least a portion of the extract and solvent. The extracted tobacco material is subjected to pyrolysis conditions to provide a pyrolyzed material. The pyrolysis conditions can include a temperature of from about 300.degree. C. to about 1250.degree. C. and a non-oxidizing atmosphere.The pyrolyzed material can then be formed into a predetermined shape such as by extrusion, casting and the like.

Abstract: With the present invention a tobacco sheet or foil is proposed which has an elevated filling force and consists of tobacco particles, water, binders and moisturizers, and relatively gas-impermeable, in particular surface-sealed cover layers being connected together by a spongy structure which is formed by gas-filled bubbles, and in which cavities are formed having a shaggy, furrowed and/or torn surface.

Abstract: A sheet tobacco producing apparatus comprises a mixer, a kneader, a crusher, and a shaping machine. The mixer mixes tobacco chips with auxiliary substances including water, to produce wet round pieces. The kneader has a pair of rollers for kneading the wet round pieces to form a sheet intermediate. The crusher crushes the sheet intermediate to form crushed wet round pieces. The shaping machine has a pair of rollers for forming a final sheet product from the crushed pieces. Since the tobacco raw material is deformed from the sheet intermediate which is obtained after once kneaded, to round pieces again, it is easy to take the material iinto the gap between the rollers of the shaping machine, whicn increases the manufacturing speed of the apparatus.

Abstract: Processed smokable materials are provided by forming a slurry of combustible material (e.g., a carbonaceous material) in an aqueous liquid. The slurry then is contacted with a foaming agent which includes a mixture of a surfactant and a polymeric film-forming agent. The slurry is agitated to provide a slurry of decreased density. The slurry so provided then is formed into the desired shape and dried. The processed smokable material which results is useful as cut filler for cigarette manufacture.

Abstract: A dried, concentrated fiberless aqueous extract of cured tobacco leaves suitable for smoking or chewing and a process for producing same.

Abstract: Reconstituted tobacco has phosphate salts incorporated therein. Tobacco is extracted with water to yield an insoluble portion and an aqueous portion containing water soluble tobacco components. The aqueous portion is adjusted to a pH of about 7, and contacted with diammonium hydrogen orthophosphate. The extract then is applied to the insoluble portion which has been formed into a sheet-like shape. The resulting tobacco composition is dried to yield a reconstituted tobacco material.

Abstract: A flavor source to be used as a thermally releasable flavorant for smoking articles that do not combust tobacco. The material includes tobacco particles, an aerosol precursor that forms an aerosol upon exposure to heat, and a filler material that absorbs and radiates heat to minimize the likelihood that the flavor material will ignite. The material is mixed in an extruder, extruded through a die, and cut into pellets having a substantially uniform shape. The pellets are loaded into a chamber for inclusion in a smoking article as a flavor generator.

Abstract: An apparatus and method for manufacturing tobacco sheet material comprising the steps of acoustic mixing with ultrasonic vibration a slurry containing tobacco components and forming sheets of tobacco material by casting the slurry after acoustic mixing. Additionally, the slurry is mixed with subsonic vibration and low shear mixing before the slurry is acoustic mixed. The slurry may include sized tobacco stems, sized tobacco dust and extract solution.

Abstract: Reconstituted Tobacco has ammonia incorporated therein. Tobacco is extracted with water to yield an insoluble portion and an aqueous portion containing water soluble tobacco components. The aqueous portion is contacted with ammonia to yield an ammoniated extract. The extract is applied to the insoluble portion which has been formed into a sheet-like shape. The resulting tobacco composition is dried to yield a reconstituted tobacco material treated with ammonia.

Abstract: Tobacco containing cigarette filter plugs comprise strands of tobacco material which are bound with an activated binding agent. The filter plugs exhibit good firmnless and integrity, and provide cigarettes exhibiting a unique tobacco taste. Filter plugs are prepared by forming an intimate admixture of tobacco material and binding agent, forming rods and activating the binding agent.

Abstract: The present invention is directed to densified particulate materials and to a process of preparing such materials.The present invention is also related to cigarette-type smoking articles utilizing the densified particulate materials of the present invention as an extender of the fuel and/or as a flavor enhancer.In cigarette-type smoking articles, the densified particulate material of the present invention may also serve as a substrate or carrier for an aerosol forming substance. The use of densified particulate tobacco, in whole or in part, as such a substrate affords many advantages heretofore unavailable in cigarette-type smoking articles.The use of the densified particulate materials of the present invention in conventional tobacco products, e.g., cigarettes, cigars, pipe tobacco, and the like, affords advantages heretofore unavailable. Preferably, a mixture of densified carbon and densified tobacco is used, both as an extender/filler and as a flavor enhancer.

Abstract: A system and method for reclaiming tobacco from rejected products and byproducts of a cigarette manufacturing operation are disclosed. The tobacco that is reclaimed from rejected cigarettes, long ends and defective packs of cigarettes is screened to separate a fraction of larger tobacco particles that can be returned directly to the cigarette manufacturing machines. The fraction of smaller tobacco particles and fines produced by the screening treatment is combined with stem material and tobacco dust recovered from the manufacturing operation to produce strands of reconstituted tobacco which are incorporated into the cut tobacco that is supplied to the cigarette manufacturing machines.

Abstract: The present invention relates to an aerosol producing substrate for subsequent use in smoking articles and to methods of preparing the aerosol producing substrate. Preferred smoking articles which employ the aerosol producing substrate of the present invention are capable of producing substantial quantities of aerosol, both initially and over the useful life of the product, without significant thermal degradation of the aerosol former and without the present of substantial pyrolysis or incomplete combustion products or sidestream aerosol. Thus, such smoking articles provide the user with the sensations and benefits of cigarette smoking without burning tobacco.

Abstract: The process is carried out using an apparatus including two pressurized roller systems, each roller system having two rollers in roll contact. A series of generally "V" shaped grooves extends about the periphery of one roller of the first roller system, while the other roller thereof has a smooth surface. The two rollers of the second roller system are spaced apart by a distance of about 0.002 inch to about 0.020 inch.

Abstract: Tobacco material can be processed to yield a product (e.g., sheet-like material) which can be used to yield cut filler for the manufacture of cigarettes. Tobacco material (e.g., whole leaf and/or scrap) is shear agitated in the presence of moisture of less than 30 weight percent. The shear agitation is performed in the absence of externally added binding agents. The sheared mixture is passed through a roller system in order to provide compressive treatment to the mixture. The processed mixture is further formed into the desired shape. Tobacco material can be provided using energy efficient processing steps, and without waste of tobacco material.

Abstract: Tobacco extender material is provided in sheet-like form by contacting tobacco material and/or carbonized material in substantially dry form with a binding agent in substantially dry form, and then subjecting the mixture to a high rate of shear agitation in the presence of a relatively low moisture content. The level of moisture is sufficient to provide activation of the binding agent. The material so processed is further processed using dry forming techniques in order to provide sheets of reconstituted tobacco material and sheets of carbonized material. The sheets of tobacco extender can be cut to the desired size and is useful in the manufacture of cigarettes.

Abstract: Tobacco extender material is provided in strand form by contacting tobacco material and/or carbonized material in substantially dry form with a binding agent in substantially dry form, and then subjecting the mixture to a high rate of shear agitation in the presence of a relatively low moisture content. The material so processed is further processed using dry forming techniques in order to provide strands of reconstituted tobacco material and strands of carbonized material. The strands of tobacco extender are useful in the manufacture of cigarettes.

Abstract: A method and apparatus for coating reconstituted tobacco are provided. A web of reconstituted tobacco is coated on both sides with slurries of tobacco particles in tobacco sizing liquor. A forward roll coater coats one side, and supports the web while a reverse roll coater coats the other side. The web adheres to the forward roll coater by virtue of the presence of the coating on the first side, so that the reverse roll coater does not tear the wet, relatively weak web.

Abstract: Whole leaf tobacco can be processed to yield a sheet-like product which can be used to cut filler for the manufacture of cigarettes. Whole leaf tobacco including stem is shredded and contacted with a binding agent in dry form. The essentially dry mixture is shear agitated in the presence of moisture less than about 30 percent, based on the total weight of moisture, binding agent and tobacco. The divided tobacco is subjected to the high shear agitation in the presence of sufficient moisture to provide for activation of the binding agent. The sheared mixture is passed through a roller system to provide compressive treatment to the mixture. The processed mixture is further formed into a sheet-like shape. Tobacco material can be provided using low amounts of binding agent, using energy efficient processing steps, and without waste of tobacco material.

Abstract: A process for manufacturing reconstituted tobacco from tobacco stems and tobacco fines includes treating the tobacco stems to a fibrous form, and mixing the fibrous tobacco stems with tobacco lamina fines. The mixture is then deposited on a moving mesh screen whereon it is formed into a felt-like mat or sheet of generally uniform thickness. The reconstituted tobacco sheet is then removed from the mesh screen for further processing to produce a tobacco smoking article.

Abstract: A process for reclaiming tobacco comprises providing tobacco material including relatively large fibrous forming tobacco leaf stem material, passing the tobacco through a pressurized roller system, and forming a reclaimed tobacco material under pressure. Tobacco stems, fines, dust and waste can be reconstituted in strand form or sheet-like form using a process which utilizes relatively low amounts of moisture.

Abstract: An improved method of reducing the nitrate, nitrite and ammonium compound content of an aqueous tobacco extract employing microorganisms is described. The nitrates, nitrites and ammonium compounds are eliminated on a continuous basis via an aerobic assimilatory metabolic pathway by introducing aqueous tobacco extract and necessary additives into a work mixture, containing suitable microorganisms, at a dilution rate which does not exceed the growth rate of the microorganisms while withdrawing a portion of the work mixture at a rate such that the volume of the work mixture remains constant. Optionally the biomass may be removed from the withdrawn mixture.

Abstract: A smokable, coherent sheet of disintegrated vegetable materials and/or tobacco waste, said sheet being provided with a water-insoluble film on one surface and being obtained in that the vegetable materials and/or tobacco waste are pressure-formed with binding agents and water, the share of which is lower than that of the dry substance employed, between forming elements, the formed, coherent and still moist sheet is coated at a moisture content of 30 to 50% with a solution or suspension having at least one water-soluble, modified pectin from the group of low-esterified pectin with an esterification degree of below 40% and/or amidified, low-esterified pectin with an amidation degree of over 15%, the modified pectin is contacted with bivalent and/or trivalent metal ions and the coated sheet is dried, with the concentration of the modified pectin on the sheet surface being at least 0.5 percent by weight, as referred to the dry weight of the finished product.

Abstract: A process for the reduction of the nitrate and nicotine contents of tobacco by microbial treatment is disclosed wherein tobacco materials are subjected, under controlled conditions, to the action of a microorganism effective to degrade nitrates and alkaloids (nicotine) through a biochemical reaction. The microorganism is combined or grown in the presence of a nitrate containing compound in relatively small quantities. Tobacco treated in accordance with this process has a reduced nitrate and nicotine content, and when incorporated into a tobacco smoking product thereby produces a mild smoke, having reduced nitrogen oxides, hydrogen cyanide and nicotine content. However, there is no loss of desirable flavor, taste and smoking properties.

Abstract: A process for the reduction of the nitrate content of tobacco materials by microbial treatment is disclosed wherein tobacco materials are subjected, under controlled conditions, to the action of a microorganism effective to degrade nitrates through a biochemical reaction. Tobacco materials treated in accordance with this process, when incorporated into a tobacco smoking product, produce a mild smoke having reduced nitrogen oxides and hydrogen cyanide deliveries without loss of desirable flavor, taste or other smoking properties.

Abstract: An improved method of making reconstituted tobacco using a dry-forming process. Fiberized tobacco stems and scrap are combined with tobacco material of a fine particle size. The resulting tobacco mixture is conveyed in an airstream and deposited on a moving foraminous surface. An adhesive is incorporated into or applied to the web bonding the tobacco particles into a coherent sheet, and the sheet is dried if necessary. The dried sheet may be divided into leaflets or shredded for further processing as reconstituted tobacco. In preferred embodiments, cellulose fibers are mixed with the tobacco particles prior to web formation to impart increased sheet strength. In a further embodiment tobacco fines are mixed with the adhesive and applied to the web in the adhesive composition. Results obtained by means of the present invention include cost savings particularly in terms of reduced capital costs.

Abstract: A combustible smoking material having a color other than that of conventionally cured tobacco leaves is coated with finely divided vermiculite that has previously been subjected to heat treatment to develop a brown color therein. The vermiculite coating imparts a tobacco-like brown color to the combustible smoking material.

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: A tobacco product with a high specific volume and particularly suited for use as cigarette or cigar filler produced by laminating together two sheets of reconstituted tobacco sheet under conditions so that the resulting laminate, after shredding, contains shreds in which the plies are only partly adhered and partly separated, whereby a filler having substantially increased filling power is produced as compared with conventional reconstituted tobacco sheet.