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: Reconstituted tobacco having good wet strength is provided. Tobacco material is extracted with water to yield an insoluble portion and an aqueous portion containing water soluble tobacco components. The insoluble portion is formed into a sheet-like shape and contacted with a pectin release agent. Alternatively, the insoluble portion is contacted with pectin release agent and then formed into a sheet-like shape. 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: The present invention relates to a method for providing a reconstituted tobacco material. The process includes contacting tobacco material with a liquid having an aqueous character to provide a mixture (slurry). The slurry is then contacted with a pectin release agent. The tobacco material having released tobacco pectins is then formed into a predetermined shape. The formed slurry having released tobacco pectins is subjected to conditions sufficient to crosslink the released tobacco pectins (e.g., contacting with a crosslinking agent). The formed slurry having crosslinked tobacco pectins is dried to provide a reconstituted tobacco material.

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: Reconstituted tobacco material is provided by extracting tobacco material using water to provide an insoluble portion and an aqueous extract. The insoluble portion is formed into a sheet-like shape. The aqueous extract is blended with a further tobacco extract which is provided by treating Burley tobacco strip with ammonia and steam. The aqueous tobacco extract and further tobacco extract optionally can be heat treated, contacted with a water soluble phosphate salt, and/or contacted with levulinic acid. The aqueous extract and further tobacco extract are combined with the insoluble portion, resulting in a reconstituted tobacco material. The reconstituted tobacco material is blended with other tobacco materials and employed as cut filler in cigarette manufacture.

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 contacted with diammonium hydrogen orthophosphate and adjusted to a pH of about 6.5. 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: Reconstituted tobacco material is provided by forming a slurry of tobacco dust in water and providing the slurry at a near neutral pH. The slurry is contacted with diammonium hydrogen orthophosphate, and the slurry is maintained at about 140.degree. F. for about 1 hour. The pH of the slurry then is increased to about 8, and the slurry is maintained at about 180.degree. F. for about 5 minutes. The slurry then is subjected to shear treatment, cast as a sheet, and dried. The resulting reconstituted tobacco material is useful as cut filler for cigarette manufacture.

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 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.