GEL-COATED NOVEL PORTION SNUS

Abstract

A pre-portioned snus product comprising a portion of snus tobacco and a coating is disclosed.

Description

BACKGROUND

There exists a need in the art for a snus product that provides rapid flavor delivery yet fits comfortably in a user's mouth.

SUMMARY

Provided is a pre-portioned snus product comprising a coating comprising a water-soluble, non-cross-linked component and a substantially water-insoluble, cross-linked component; and a collection of particles of snus tobacco particles at least partially enclosed by said coating, wherein the pre-portioned snus product is sized for placement in a user's mouth and wherein the pre-portioned snus product is adapted to provide, during oral enjoyment of the product, tobacco solutes

In another embodiment is provided a method of forming a pre-portioned snus product comprising forming a portion of snus tobacco particles to form a pre-portioned snus; contacting the pre-portioned snus with a multi-component aqueous coating solution comprising a water-soluble, non-cross-linkable polymer and a cross-linkable polymer which forms a substantially water-insoluble polymer upon cross-linking to form a coating on said portion of moist plant material; and cross-linking said cross-linkable polymer to form a semi-dissolvable, coating on the surface of the pre-portioned plant material, wherein the pre-portioned snus product is adapted to provide, during oral enjoyment of the product, tobacco solutes.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a cross-sectional schematic illustration of one embodiment of a snus product with a coating.

DETAILED DESCRIPTION

Snus differs from other types of orally-enjoyable tobacco in that portions of snus tobacco have a size and nicotine concentration that permits the swallowing of the tobacco solutes produced during oral enjoyment of the product. In contrast, other forms of orally-enjoyable tobacco generally contain a greater quantity of nicotine in a single portion, so as to make the swallowing of the solutes thereof undesirable to most consumers.

Snus has been conventionally been provided either in loose form or in pouches. Although pouched snus is not generally swallowed, the tobacco in the pouches has a nicotine content similar to that of loose snus.

While many consumers enjoy loose snus products with high moisture levels, taking the moist snus portions by finger tends to be messy and also disperses the tobacco to some extent in the mouth, which may be undesirable. Pouched products address these issues by containing the moist, loose snus in a porous, sealed pouching material similar to that in teabags. However, many snus consumers dislike traditional pouches because they perceive pouches to be dryer, less flavorful, lower in tobacco character, lower in chemesthetic sensation, slower and more difficult to extract “tobacco juice,” less comfortable in the mouth, and/or more irritating to cheek and gum. Thus the need is evident for a thin, smooth, high moisture material which does not block fast flavor delivery, but which can serve to contain a portion of snus tobacco at least until it is placed in the mouth.

Pre-portioned, pouchless products of plant material, such as tobacco, are described in commonly-owned U.S. Patent Application Publication Nos. 2008/0202533, 2009/0038631, and 2009/0301505, each of which is incorporated by reference.

Disclosed herein is a snus product wherein a hydrated coating surrounds a molded shape of snus tobacco. It has been found that some coatings of snus tobacco exhibit various drawbacks with respect to flavor release and/or ability to contain the tobacco. For instance, it has been determined that some coating materials are not comfortable in a user's mouth, while others provide too rapid a flavor release or too much moisture. To help overcome drawbacks such as these, the coating described herein has been developed, which allows the flow of flavor juices from the snus tobacco, as well as any added flavors, into the user's oral cavity. The product described herein also allows for the formation of a pre-portioned snus product that is easily placed in the mouth.

As used herein, the term “pre-portioned” refers to snus tobacco that has been molded or divided into individual servings prior to use, such that the pre-portioned snus tobacco can be placed in a user's mouth without the need for the user to determine an amount to use. It is intended to include collections of snus particles that have been pressed or molded or otherwise formed into one or more shapes that are convenient for a user to recognize, manipulate, and/or comfortably insert into the oral cavity and consume, and which contain an amount of snus similar to that commonly used by users of smokeless tobacco products. The terms “pre-portioned snus” as used herein refers to the snus tobacco exclusive of the coating. The term “pre-portioned product” as used herein refers to the coated snus product as a whole, i.e., to the pre-portioned snus tobacco material and its coating.

In an embodiment, termed “easy in, loose out,” the product quickly breaks up into individual particles once the non-cross-linked components of the coating dissolve on exposure to the user's saliva. This allows for immediate release of snus tobacco and its flavors, thereby providing an experience similar to that of loose snus, but with the added convenience of the pre-portioned format.

In another embodiment, termed “easy in, easy out,” the coating around the product remains substantially intact during oral enjoyment thereof. This reduces or eliminates free-floating snus particles in the oral cavity, thus providing an aspect similar to that provided by traditional pouches.

As used herein, the terms “particle” or “particles” denote any subdivided form of tobacco, and can include flakes, granules, powders, chopped stems, leaves, or other pieces of tobacco.

As used herein, the term “substantially water-insoluble” denotes a material that has a significantly lower solubility in water than the non-cross-linked water-soluble polymers described herein.

FIG. 1 illustrates a cross-sectional schematic view of an embodiment of a pre-portioned snus product 10 with a coating 12. The coating 12 is a single layer coating that coats a pre-portioned amount of snus tobacco 16. The coating 12 includes a soluble polymer and an insoluble polymer, which may be the same or different. Snus tobacco 16 is a collection of snus particles that have been formed into a suitable size and/or shape. Preferably, the snus tobacco 16 is a molded portion of snus tobacco of a size suitable for consumption by an individual.

The portioned product 10 is preferably appealing to both sight and touch, and is strong enough to maintain the integrity of a portion through placement in the mouth. Preferably, the product 10 is not messy or sticky to the touch and can be easily placed into the mouth. The product thus meets the goals of facilitating portioning, placement, and providing enhanced flavor/moisture in the initial moments of use.

Preferably, the pre-portioned snus product 10 is sized and configured to fit comfortably between the user's cheek and gum while being is flexible, compressible, and capable of conforming to the shape of the oral cavity. The pre-portioned snus product 10 may be formed in many shapes including, without limitation, spheres, rectangles, oblong shapes, crescent shapes, ovals, and cuboids. Preferably, the pre-portioned snus product comprises about 2.5 grams to 0.2 grams of snus tobacco, more preferably about 1.0 grams to about 0.25 grams, still more preferably, and yet more preferably about 0.5 to 0.3 grams. In a preferred embodiment, the bulk density of the product 10 is about 1.0±0.2 g/cm³

The snus tobacco preferably has a moisture content of about 6 to about 30% by weight or about 45% to 55% by weight, more preferably at least 12% by weight, most preferably at least 20% by weight. For example, the product may have a moisture content of about 12% to 20% by weight. It was found that storage of snus products with less than about 12% moisture resulted in partial drying of the hydrated coating, so that the coating was undesirably slow to rehydrate after being placed in the mouth of a consumer.

Snus tobacco generally contains less nicotine than other types of smokeless tobacco. Snus tobacco preferably contains between about 5% and 0.5% nicotine by weight, more preferably between about 3% and about 1%, still more preferably between about 2.5% and about 1.5%, and most preferably about 2%. These percentages are on a dry weight basis.

The amount of snus tobacco 16 in an individual snus product 10 contains a quantity of nicotine that would be acceptable for a consumer to swallow, even if the product itself is not intended to be swallowed. For example, an individual portion of snus product 10 preferably contains 20 mg or less of nicotine, more preferably about 10 to 4 mg of nicotine, most preferably about 5 to 4 mg of nicotine.

The coating 12 can be thermally set (for example, by including agar with or without other polysaccharides) or ionically gelled. The coating 12 can optionally carry flavors, sweeteners, and/or chemesthesis agents.

In an embodiment, the coating can be made in an outward-to-inward direction by ionic cross-linking of one or more polysaccharides to create a thin, membrane-like coating over a portion of snus. This technique delivers a relatively firmer coat that appears dry to the touch and sight, and has a relatively firm, cross-linked coating at the air-coating interface.

Outward-to-inward direction cross-linking experiments were carried out by taking a portion of snus tobacco and molding it into predefined shape such as a ball or rectangle. The molded snus was dipped into a solution of film-forming polysaccharide (such as alginate, pectin, or carrageen), followed by crosslinking by contacting the dipped, molded snus with a metal ion salt such as calcium lactate. The thickness of the coating (which in turn helps control the porosity of the coating) can be controlled by varying the concentration of the polysaccharide solution. Additionally, the crosslinking agent can be patterned on snus preform or overprinted and/or sprayed to form a mesh of stronger crosslinked material around more dissolvable non-crosslinked polysaccharide.

In another embodiment, cross-linking of the coating material occurs from an inward to outward direction, a process sometimes referred to as “in-situ coating.” Generally speaking, such crosslinking occurs when a solution of coating material contacts at least one metal ion present within and/or on the surface of the preformed snus. Such metal ions can be endogenous and/or added to the snus. This embodiment allows for control of the coating thickness which in turn can control the porosity of the coating. This technique delivers a relatively softer exterior coating that is moist to the touch and also visibly moist, and has the relatively firmer cross-linked coating at the tobacco-coating interface.

Because snus tobacco naturally contains salts such as calcium ions, the calcium ions preferably cross-link with the cross-linkable polymer to form a skin or shell on the inside of the coating once the tobacco material has been contacted with the two polymer solution. Later, when the coating is exposed to a cross-linking agent, an outer skin or shell can form on the coating. The inner and outer skins or shells provide a moisture barrier for the tobacco and the soluble portion of the coating. Preferably, the shells/skins are formed of a discontinuous, cross-linkable polymer with regions of the non-cross-linkable polymer incorporated therein.

Experiments in inward-to-outward (in-situ) coating were carried out by taking a portion of the snus tobacco with or without mixing with an aqueous solution of a metal ion salt such as calcium lactate, and molding the portion into predefined shape such as a ball or cuboid. The molded portion was dipped into a solution of a film-forming polysaccharide (such as alginate, pectin, and/or carrageen). The coating thickness is determined by the viscosity of the coating liquid, which is determined by a number of factors including the type and concentration of coating materials (the film-forming polysaccharide), the degree of pre-gelling and/or cross-linking, shear history, and temperature. Increased thicknesses can be generated by multiple coating applications. The coating is hydrated as it is formed. Optionally, the coating process can be automated by spraying a polysaccharide solution and a metal ion salt solution alternately onto a preformed shape of tobacco to create a cross-linked, membrane-like coating of desired thickness.

In an embodiment, the coating is two-component coating including a water-soluble, non-crosslinked component and a cross-linked polymer component. This produces a semi-dissolvable coating, sometimes termed a super-hydrated membrane coating, that at least partially encloses the snus tobacco. The coating takes the form of a monolayer and is hydrated as it is formed. The cross-linked polymer is substantially water-insoluble and optionally, the substantially water-soluble component is a polymer and/or is non-cross-linkable. The portions preferably do not have a wrapper.

By controlling the relative amounts of the water-soluble, non-crosslinked component and the cross-linked polymer, the portion can be adapted either to break apart in the user's mouth (easy in, loose out) or to remain intact in the user's mouth (easy in, easy out). In the latter case, after the soluble component dissolves in a user's mouth, the coating creates a porous network composted of a substantially insoluble polymer.

Accordingly, in an embodiment, the soluble component dissolves rapidly in a user's mouth such that the substantially insoluble cross-linked polymer component remains intact throughout use of the product, so that the coating allows the snus tobacco juices and flavors to leech out of the coating, while still remaining intact to hold the tobacco within the coating through the duration of tobacco use while providing a soft compliant feel to the tongue and mouth tissues. Because in this embodiment the coating acts to contain the snus tobacco while it is in the user's mouth, if and when the user desires to remove the portion from the mouth, this can be easily accomplished.

In further embodiment, the snus tobacco material is completely disintegrable so that once the soluble component of the coating dissolves and tobacco material has disintegrated, a user may chew and either spit out or ingest the remaining insoluble component. The coating desirably contains a minority amount of the substantially water-insoluble, cross-linked polymer, which minority amount is insufficient for the pre-portion to retain its structural integrity in the user's mouth after the water-soluble, non-cross-linked component has dissolved. Thus, the particles of snus tobacco contained within the coating are released and/or dispersed in the user's mouth once the water-soluble component dissolves and the pre-portioned form disintegrates.

The coating may be applied to the moist pre-portioned tobacco by a variety of techniques, which can include dipping, spraying, and the like. The coated pre-portioned tobacco is then contacted with a cross-linking agent suitable for the cross-linkable polymer or polymers employed in the coating. This contact can result from application of the cross-linking agent to the coated portion, e.g., by spraying, dipping, or other application of a solution of cross-linking agent to the coated portion (resulting in an “outside-in” direction of cross-linking). Alternatively, cross-linking can result from contact of the cross-linkable polymer with cross-linking agent already present in the tobacco, either as the result of cross-linking agent present in the tobacco before it is formed into a pre-portion, or as the result of the application of cross-linking agent to the pre-portion prior to application of the coating.

Preferably, the coating is aesthetically pleasing, non-tacky, and pleasant to touch, while being strong enough to maintain the integrity of the portion of snus tobacco material contained inside the coating during insertion and placement in the mouth.

The coating is preferably clear, but additives may be used to provide the coating with a desired color or appearance. For example, fillers may be added to the coating to make the coating opaque, and/or colorants may also be added to alter the color of the coating.

The coating is preferably in the form of a gel, more particularly in the form of a hydrogel. As a result, a significant portion of the weight of the coating is water, as compared to weight contributed by the water-soluble non-crosslinked component and the substantially water-insoluble cross-linked polymer, as well as cross-linking agents, and any additives, such as preservatives, flavorants, etc. In a preferred embodiment, the weight of the coating when completely dried is about 0.013 g for a coated tobacco product weighing about 2.5 g. In contrast, the weight of the same coating before drying, when the coating is at the preferred moisture content, is about 0.15 g.

Because only the water-soluble, non-cross-linked component of the coating dissolves and releases moisture into the user's mouth, the amount of moisture released is controlled, and is not excessive. This provides the user with decreased slipperiness and improved mouthfeel when using the product.

Preferably, the water-soluble, non-cross-linked component dissolves rapidly in a user's mouth. In a preferred embodiment, the soluble component dissolves in about 0.1 seconds to about 10 seconds (e.g., about 1 second to about 9 seconds, about 2 seconds to about 8 seconds, about 3 seconds to about 7 seconds or about 4 seconds to about 6 seconds) after introduction into the oral cavity. Also preferably, the pre-portioned form loses its structural integrity within about 5 to about 15 seconds (e.g., about 6 to about 14 seconds, about 7 to about 13 seconds, about 6 to about 12 seconds, about 7 to about 11 seconds or about 8 to about 10 seconds) after introduction into the oral cavity.

The water-soluble component and substantially water-insoluble component may be natural or synthetic. Preferably the components are hydrocolloids. More preferably, the components are polysaccharides.

Optionally, the water-soluble component comprises a non-cross-linked and/or non-crosslinkable polymer. In an embodiment, the water-soluble component can be formed by a cross-linkable polymer, which has not reacted with a cross-linking agent. Suitable water-soluble non-crosslinked components include, without limitation, starch and starch derivatives, such as modified starch, dextrin, gums, such as gum arabic, guar gum, xanthan gum, locust bean gum, curdlan gum, gellan gum, fenugreek derivative gums, pullulan, chitosan, chitin, cellulose and cellulose derivatives, synthetic polymers, such as polyvinyl alcohol, polylactide, polyethylene glycol, polyvinylpyrrolidone, or polyvinylacetate, and soluble or insoluble vegetable fiber.

Suitable chemically cross-linkable polymers include, without limitation, alginate, pectin, carrageenan, and modified polysaccharides with cross-linkable functional groups. Preferred cross-linkable polymers are pectins and alginates. Proteins, for example gelatin, zein, soy protein, rice protein, and whey protein, can optionally be used to supplement or replace the cross-linkable polymers that are cross-linked with monovalent and bivalent metal ion salts. The proteins slowly cross-link with phenolics and/or aldehydes that occur naturally in tobacco.

At least one tobacco-based polysaccharide, for example, pectin, is preferably used in the coating. Such tobacco based material may optionally be highly purified to remove flavorful tobacco compounds in order to modify the tobacco flavor character to initial in-mouth experience. Additional dissolvable tobacco such as extractives or colloidal encapsulated tobacco can be added to the coating to increase the initial tobacco flavor/character in the first stages of dissolution. Use of coating material obtained from tobacco may provide an economic advantage by allowing for the use of material that might otherwise go to waste. Information regarding tobacco-sourced polysaccharides may be found in U.S. Pat. Nos. 4,034,764; 4,143,666; 4,972,854; 4,506,684; and/or 5,724,998, each of which is incorporated herein by reference.

In a preferred embodiment, the cross-linking agent is a polyvalent metal salt, more particularly, a monovalent metal ion salt or bivalent metal ion salt. While, both monovalent and bivalent metal ion salts may be used, a bivalent metal ion salt is particularly suitable for crosslinking certain polysaccharides, such as pectins. Suitable cross-linking agents include, without limitation, calcium lactate, calcium chloride, calcium lactobionate, tricalcium phosphate, calcium glycerophosphate, calcium hexametaphosphate, calcium acetate, calcium carbonate, calcium bicarbonate, calcium citrate, calcium gluconate, sodium chloride, sodium lactate, sodium acetate, sodium carbonate, sodium bicarbonate, sodium citrate, sodium gluconate, potassium chloride, potassium lactate, potassium acetate, potassium carbonate, potassium bicarbonate, potassium citrate, potassium gluconate and combinations of these.

Suitable flavor additives and aromas for inclusion in the coating or the tobacco material include, but are not limited to, any natural or synthetic flavor or aroma, such as tobacco, smoke, menthol, peppermint, spearmint, bourbon, scotch, whiskey, cognac, hydrangea, lavender, chocolate, licorice, citrus and other fruit flavors, such as apple, peach, pear, cherry, plum, orange and grapefruit, gamma octalactone, vanillin, ethyl vanillin, breath freshener flavors, spice flavors such as cinnamon, clove, nutmeg, sage, anise, and fennel, methyl salicylate, linalool, jasmine, coffee, bergamot oil, geranium oil, lemon oil, and ginger oil. Other suitable flavors and aromas may be selected.

The coating may also include additives such as natural or artificial sweeteners. Preferred sweeteners include, without limitation, water soluble sweeteners, such as monosaccharides, disaccharides, and polysaccharides, such as xylose, ribose, sucrose, maltose, fructose, glucose, and mannose. Other preferred sweeteners include xylitol (birch sugar). Sweetness potentiators or modulators such as thaumatin can be added. Sweeteners, sweetness potentiators, and/or modulators are optionally encapsulated to more precisely control the sweetness profile over the use of the product.

Additives such as chemesthesis agents may also be included in the coating. Suitable chemesthesis agents for inclusion in the coating include, without limitation, menthol, capsaicin, tannins, mustard oil, wintergreen oil, cinnamon oil, allicin, quinine, citric acid, and salt. Xylitol also provides a chemesthetic cooling effect.

In a preferred embodiment, the super-hydrated membrane coating may be provided with a desired rate of dissolution of the soluble component of the coating by altering the proportion of the soluble component to the insoluble component.

In a preferred embodiment, the super-hydrated membrane coating is not messy or sticky to the touch. Because at least two polymers are used to create the coating, when a user touches the coating, the polymers do not disassociate from one another. Therefore, the coating is not sticky when the product is removed from a package and placed in the mouth.

The tobacco material 16 may be provided in any suitable form, including shreds and/or particles of tobacco lamina, processed tobacco materials, such as volume expanded or puffed tobacco, or ground tobacco, processed tobacco stems, such as cut-rolled or cut-puffed stems, reconstituted tobacco materials, blends thereof, and the life. Genetically modified tobacco may also be used.

Additionally, the tobacco material may also include a supplemental amount of vegetable or plant fibers or particles, such as particles of shreds of lettuce, cotton, flax, beet fiber, cellulosic fibers, blends thereof and the like, and/or expended (post-extracted) botanical substrates such as mint leaves or tea.

The concentration of the polymer solution determines the thickness of the coating membrane. The thickness of the coating can in turn affect how quickly the soluble component of the coating dissolves in a user's mouth. The coating is a moist, gel-like coating when formed and the moistness is preferably retained until use. Preferably, the coated tobacco product is hermetically sealed in suitable packaging to prevent moisture in the tobacco and coating from evaporating.

If the coating is peeled off of the tobacco product and completely dried, the coating is preferably about 0.02 mm to 1.0 mm thick. More preferably, when the coating is completely dried, it is about 0.08 mm to 0.14 mm thick. In a most preferred embodiment, the coating when completely dried is about 0.11 mm thick. It should be noted that the coating is not intended to be dried, but rather retains a high moisture content.

After the coating is applied, the tobacco product is exposed to air or patted dry to evaporate excess moisture. The drying of the coating results in the migration of fluids containing tobacco flavor from the interior towards and/or into the coating, resulting in a superior tasting coating. Additional water can be added to the tobacco to facilitate this flavor migration to the coating during drying. The rate of drying controls the migration: slow drying increases migration, and faster drying decreases migration. The tobacco product is preferably not dried extensively, so that the super-hydrated coating retains a high moisture content.

In another embodiment, the polymer solution and the cross-linking solution can be patterned, overprinted, or sprayed onto the tobacco material preform to form a network having a soluble component and an insoluble component. The polymer solution may include a chemically, cross-linkable polymer and a non-cross-linkable polymer. Alternatively, the polymer solution may include a single chemically, cross-linkable polymer. When a single polymer is used, the cross-linking solution may be selectively sprayed to leave some portions of the coating non-cross-linked and soluble. The soluble component of the coating may dissolve, leaving a porous network of insoluble component in place to maintain coherence of the tobacco material, while allowing the free flow of saliva in the user's mouth.

In an embodiment, the process may be automated. For instance, the coating step may occur via spraying the polymer solution and the cross-linking solution alternately onto a preformed portion of tobacco material to create a cross-linked, thin, super-hydrated membrane coating of a desired thickness.

In one embodiment, dissolvable tobacco such as tobacco extracts or colloidal encapsulated tobacco can be added to the coating to increase the initial tobacco flavor in the first stages of the dissolution of the super-hydrated membrane coating.

The portions produced as described above may optionally be pasteurized by high temperature/short time (HIST) or ultra-high temperature (UHT) procedures.

Snus portions may be packed in containers similar to those used in paper pouch products, or optionally in a sterilized blister pack. Preferably, portions are hermetically sealed in suitable packaging to prevent moisture in the tobacco and coating from evaporating.

1. Easy-in, Loose-Out Portions

The follows relates primarily to portions that break apart in the mouth (this trait sometimes described as “easy-in, loose-out”), however aspects may apply to other types of portions.

In an embodiment, when preparing portions that break apart in the mouth (such a trait sometimes being termed “easy-in, loose-out”), the water-soluble non-crosslinked component is included in an amount of about 15% to about 30% by weight based on the weight of the coating solution, and the cross-linkable polymer which forms a substantially water-insoluble polymer upon cross-linking is included in an amount of about 0.3% to about 1.5% by weight based on the weight of the coating solution. If less than about 15% water-soluble component is used in the coating solution, the pre-portioned product will tend to break up into large chunks upon dissolution of the water-soluble, non-cross-linked polymer. If more than about 30% of the coating solution is the water-soluble non-cross-linked polymer, the pre-portioned product will tend to break apart completely.

Once placed in the mouth, the soluble, non-cross-linked component dissolves. The substantially insoluble, cross-linked component is insufficient to hold the particles of tobacco together, so that the tobacco is released and/or dispersed in loose form in a user's mouth. The result is a pre-portioned snus tobacco product which has sufficient structural integrity to be handled and inserted into the mouth by the user, but which breaks up after insertion in the user's mouth, to replicate the experience of using loose snus tobacco.

Preferably, the substantially water-insoluble component is formed by reacting a chemically cross-linkable polymer with a cross-linking agent. Preferably, the coating solution includes the substantially water-insoluble component in an amount of about 0.3% to about 1.5% by weight based on the weight of the coating solution. If less than about 0.3% substantially water-insoluble component is used in the coating solution, the pre-portioned product will be too weak for a user to handle when placing in the mouth, and will break apart. If a coating contains more than about 1.5% substantially water insoluble component, the coating will provide greater structural integrity to the product, so that it will tend not to break apart and disperse the tobacco material in the user's mouth.

By using both a non-cross-linkable polymer and a cross-linkable polymer, the porosity and strength of the super-hydrated membrane coating can be controlled. For instance, the dissolution rate of the resulting super-hydrated membrane coating can be altered by modifying the specific proportion of cross-linked to non-cross-linked polymers. In a preferred embodiment, the coating contains 10 to 90 wt % of the cross-linked polymer. Preferably, the proportion of cross-linked polymer in the coating is 60 to 70 wt %.

The amount of cross-linking agent used will depend to a large extent on the amount of cross-linkable polymer included in the coating mixture. For the preferred amounts of cross-linkable polymers disclosed herein, preferably, the cross-linking agent is included in a cross-linking solution of about 0.5 wt % to about 2.0 wt %, based on the total weight of the cross-linking solution, more preferably about 0.5 wt % to about 1.5 wt %. Using less than 0.5 wt % cross-linking agent will generally not provide enough cross-linking agent to react with the amounts of cross-linkable polymer included in the coating mixture, which tends to result in a weak coating that will not provide the pre-portioned product with sufficient structural integrity for user handling when retrieving the product and positioning it in the oral cavity. Using more than about 2.0 wt % is unnecessary due to the low amount of cross-linkable polymer present, thereby adding unnecessary cost to the product, and may adversely affect the flavor of the product.

Once the water-soluble component of the coating dissolves, flavors and water are released into the user's mouth and the pre-portioned product loses its structural integrity so that the tobacco enclosed by the coating is released. The pre-portioned product thus provides both rapid flavor release and a replication of the experience of using loose tobacco very soon after insertion into the user's oral cavity.

In addition, due to the presence of relatively small amounts of water-soluble component, excess water and juice are not released upon disintegration of the pre-portioned product. The combination of polymers in the coating, in the ranges disclosed herein, provides a soft compliant feel to the tongue and mouth tissues, and dissolves quickly, so that the sensory experience associated with snus tobacco use is rapid and unencumbered. In addition, because only small quantities of the substantially water-insoluble cross-linked polymer remain on a small quantity of the tobacco (i.e., only that quantity of tobacco that was actually in contact with the coating) after the pre-portioned product has disintegrated in the user's mouth, the tobacco that disperses is essentially uncoated. The resulting sensory experience replicates more closely what users expect from smokeless tobacco than would a product where the individual particles have been coated.

In a preferred embodiment, the coating is not messy or sticky to the touch. The at least two polymers used to create the coating remain associated with one another when subject to normal handling by a user. Therefore, the coating is not sticky when the product is removed from a package and placed in the mouth.

2. Easy-in, Easy-Out Portions

The follows relates primarily to portions adapted to remain intact in the mouth of a user (a trait sometimes described as “easy-in, easy-out”), however aspects may apply to other types of portions.

The super-hydrated membrane coating preferably creates a porous network of an insoluble polymer after the soluble component dissolves in a user's mouth. Preferably, the first component is a soluble component that dissolves rapidly in a user's mouth such that the second component, which is preferably the insoluble component, remains intact throughout use of the tobacco product.

Preferably, the soluble component is formed by a non-cross-linkable polymer. As used herein, the term “non-cross-linkable” denotes that the material does not become crosslinked to a significant extent when subjected to conditions that cross-link the insoluble component. Also preferably, the insoluble component is formed by a chemically cross-linkable polymer reacted with a cross-linking agent. The polymers of the soluble component and insoluble component may be natural or synthetic. Preferably, the polymers are hydrocolloids. More preferably, the polymers are polysaccharides.

For easy-in, easy-out portions, the water-soluble non-crosslinked component is preferably included in an amount of about 4% by weight based on the weight of the coating solution, and the cross-linkable polymer which forms a substantially water-insoluble polymer upon cross-linking is preferably included in an amount of about 4% by weight based on the weight of the coating solution.

In a preferred embodiment, the cross-linking agent is a monovalent metal ion salt or bivalent metal ion salt.

Suitable non-chemically-cross-linkable polymers include, without limitation, starch, dextrin, gum arabic, guar gum, chitosan, cellulose, polyvinyl alcohol, polylactide, gelatin, soy protein, and whey protein.

Suitable chemically, cross-linkable polymers include, without limitation, alginate, pectin, carrageenan, and modified polysaccharides with crosslinkable functional groups. The preferred cross-linkable polymer is alginate.

While, both monovalent and bivalent metal ion salts may be used, preferably a bivalent metal ion salt is used. Suitable bivalent metal ion salts include, without limitation, calcium lactate and calcium chloride. Calcium lactate is preferred since it is approved for use in food products.

Once the soluble component of the coating dissolves, pores are created in a polymer network through which the tobacco juices and flavors flow. Flavors and water are released into the user's mouth as the soluble component of the coating dissolves. The tobacco flavors and juices are then released through the pores so that the flavor experience is seamless from beginning to end.

Preferably, the pores, created when the soluble component of the coating dissolves, are large enough to allow the unencumbered flow of juices, while remaining small enough to prevent shreds or particles of tobacco from traveling through the pores and into the user's mouth. The size of the pores may be altered by patterning the coating in such a way as to ensure the soluble component is only in certain spots and in certain amounts so that once the soluble component dissolves away the pores are of a desired size.

The coating preferably encloses a pre-portioned tobacco material at least until it is inserted in the user's mouth, after which preferably it dissolves. Before it dissolves, the coating provides a soft compliant feel to the tongue and mouth tissues.

Because the soluble component of the coating dissolves quickly, the sensory experience associated with snus tobacco use is rapid and unencumbered.

Once the soluble component of the super-hydrated membrane coating dissolves or disintegrates, additional moisture and/or flavors are released into the user's mouth. Thereafter, the flavors and tobacco juices pass through the coating to provide an uninterrupted flavor experience to the user.

Snus products as described herein provide numerous advantages over the prior art. They can provide a soft, moist product that has intrinsic portion size control instead of the manual portioning required for moist of snus, with a smooth feeling in the oral cavity instead of the roughness of traditional pouched snus. Various shapes and sizes of the portions can easily be produced. The portions can provide for additional water and/or juiciness at the initial contact with the oral cavity as compared to loose snus and especially as compared to pouched snus. The coating can have additives to allow for highly flavored/chemesthetic effects in first moments of use as compared to pouched snus. Unlike pouches, the “easy in/loose out” embodiment dissolves quickly and doesn't interfere with normal use of snus. Additionally, it is possible to create an all tobacco-based portion using tobacco-sourced polysaccharides. Other advantages of products coated as described herein are described in commonly-owned U.S. Patent Publication No. 2008/0202533, incorporated herein by reference.

The portioned snus products provided herein also provide an attractive appearance for snus users: they can appear wet, organic, and natural, and thus flavorful, as opposed to a dry-appearing pouch. The use of inward to outward crosslinking can contribute to a soft/wet/organic appearance instead of a conventional hard/dry coating.

EXAMPLES

The following examples are exemplary and are not meant to limit any aspects of the embodiments disclosed herein. When a percentage is provided, it is a percent by weight, unless otherwise noted.

Examples 1 through 3 relate to easy-in, easy-out portions.

Example 1

1.5 grams snus tobacco was first molded into predefined shape and then dipped into the biopolymer coating solution (4% pectin, 4% alginate, 0.15% dextrin) followed by cross-linking with a 2.0% calcium lactate solution.

Example 2

1.5 grams snus tobacco was first mixed with 0.5 g of calcium lactate solution (2%), then molded into predefined shape followed by dipping into the biopolymer coating solution (4% pectin, 4% alginate, 0.15% dextrin).

Example 3

1.5 grams snus tobacco was first molded into predefined shape and followed by dipping into the biopolymer coating solution (4% pectin, 4% alginate, 0.15% dextrin). A gelled, membrane-like coating was formed when the metal ions diffused from loose snus into the coating material.

The following Examples 4 and 5 relate to easy-in, loose-out portions. Such products have a highly dissolvable/or disintegratable gel coating so that immediate flavor and tobacco pleasure can be experienced by consumer. The different approaches described in the above easy-in, easy-out portions can be employed, except that the noncrosslinkable coating solution or coating solution contains a lower concentration of crosslinkable agents in order to provide a weaker strength, highly dissolvable/disintegratable coating.

Example 4

1.5 grams snus tobacco was first molded into a predefined shape and then dipped into the coating solution (15% modified food starch, 1% pectin), followed by cross-linking with a 2.0% calcium lactate solution.

Example 5

The procedure of Example 5 was followed, except that the coating solution was replaced with 20% modified food starch.

In any of the above examples, or in conjunction with any other embodiments, a thermal microbial control step (pasteurization) in the preparation of the coatings can be used, and/or the portions can be subjected to UV light to control pathogens.

Although the present invention has been described in connection with preferred embodiments thereof, it will be appreciated by those skilled in the art that additions, deletions, modifications, and substitutions not specifically described may be made without departing from the spirit and scope of the invention.

Claims

1. A pre-portioned snus product for oral enjoyment comprising:

a coating comprising a water-soluble, non-cross-linked component and a substantially water-insoluble, cross-linked component; and

a collection of particles of snus tobacco particles at least partially enclosed by said coating,

wherein the pre-portioned snus product is sized for placement in a user's mouth, and

the pre-portioned snus product is adapted to provide, during oral enjoyment of the product, tobacco solutes.

2. The pre-portioned snus product of claim 1, wherein said water-soluble, non-cross-linked component is formed by a non-cross-linked polymer and wherein said non-cross-linked polymer is selected from the group consisting of starch and starch derivatives, such as modified starch, dextrin, gums, such as gum arabic, guar gum, xanthan gum, locust bean gum, curdlan gum, gellan gum, fenugreek derivative gums, pullulan, chitosan, chitin, cellulose and cellulose derivatives, synthetic polymers, such as polyvinyl alcohol, polylactide, polyethylene glycol, polyvinylpyrrolidone, or polyvinylacetate, soluble or insoluble vegetable fiber and combinations thereof.

3. The pre-portioned snus product of claim 1, wherein said substantially water-insoluble, cross-linked component is formed by cross-linking a cross-linkable polymer with a cross-linking agent and wherein said cross-linkable polymer is selected from the group consisting of alginate, pectin, carrageenan, modified polysaccharides with cross-linkable functional groups, and combinations.

4. The pre-portioned snus product of claim 3, wherein said cross-linkable polymer comprises pectin obtained from tobacco.

5. The pre-portioned snus product of claim 1, wherein the snus tobacco comprises water in about 6% to about 30% by weight, or about 12% to about 20% by weight.

6. The pre-portioned snus product of claim 1, wherein said coating further comprises:

(a) at least one sweetener, sweetness potentiators, and/or modulator;

(b) at least one chemesthesis agent;

(c) a tobacco extract,

(d) at least one vitamin;

(e) at least one nutraceutical;

(f) at least one mineral;

(g) at least one botanical extract; and/or

(h) at least one amino acid;

wherein said at least one sweetener, sweetness potentiators, and/or modulator, said at least one chemesthesis agent; said tobacco extract, said at least one vitamin, said at least one nutraceutical, said at least one mineral, at least one botanical extract, and/or said at least one amino acid are released when said soluble component dissolves.

7. The pre-portioned snus product of claim 1, wherein the product is adapted so as to quickly break up once the non-cross-linked components of the coating dissolve on exposure to the user's saliva.

8. The pre-portioned snus product of claim 1, wherein the coating is adapted so that the product remains substantially intact during oral enjoyment thereof.

9. The pre-portioned snus product of claim 1, wherein:

(a) an individual portion of said product weighs about 2.5 g to 0.2 g;

(b) the snus tobacco contains about 12% to about 20% moisture by weight; and/or

(c) the snus tobacco contains about 2.5% to about 1.5% nicotine by weight.

10. The pre-portioned snus product of claim 1, wherein the coating comprises a single layer having an inner surface in contact with the tobacco material and an outer surface which is exposed to saliva and tissue in the oral cavity when placed therein.

11. The pre-portioned snus product of claim 1, wherein the water-soluble, non-cross-linkable component comprises a starch and the substantially water-insoluble, cross-linked component comprises pectin.

12. A method of forming a pre-portioned snus product for oral enjoyment having a semi-dissolvable coating, the method comprising:

forming a portion of snus tobacco particles to form a pre-portioned snus;

contacting the pre-portioned snus with a multi-component aqueous coating solution comprising a water-soluble, non-cross-linkable polymer and a cross-linkable polymer which forms a substantially water-insoluble polymer upon cross-linking to form a coating on said portion of moist plant material; and

cross-linking said cross-linkable polymer to form a semi-dissolvable, coating on the surface of the pre-portioned plant material,

wherein the pre-portioned snus product is adapted to provide, during oral enjoyment of the product, tobacco solutes.

13. The method of claim 12, wherein said chemically, cross-linkable polymer and said non-cross-linkable polymer are polysaccharides.

14. The method of claim 12, wherein said cross-linkable polymer is selected from the group consisting of alginate, pectin, carrageenan, modified polysaccharides with cross-linkable functional groups, and combinations thereof.

15. The method of claim 12, wherein the cross-linking comprises exposing the coating to a cross-linking agent comprising a bivalent metal ion salt.

16. The method of claim 15, wherein said bivalent metal ion salt is calcium lactate.

17. The method of claim 12, wherein:

(a) the pre-portioned snus is sprayed with said polymer solution;

(b) the pre-portioned snus is dipped into said polymer solution;

(c) the cross-linking agent is applied to the coating in a pattern, and/or

(d) the plant material comprises tobacco.

18. method of claim 12, wherein the cross-linking occurs in an inward to outward direction via a crosslinker endogenous to the snus tobacco.