SMOKELESS TOBACCO PRODUCT COMPRISING PECTIN COMPONENT

Abstract

A smokeless tobacco composition configured for insertion into the mouth of a user is provided. The smokeless tobacco composition includes a tobacco material and pectin as a binder component. A process for preparing a smokeless tobacco composition configured for insertion into the mouth of a user is also provided. The method involves extracting pectin from a first tobacco material and incorporating it into a formulation comprising a second tobacco material to form a smokeless tobacco product comprising tobacco-derived pectin.

Description

FIELD OF THE DISCLOSURE

The present disclosure relates to products made or derived from tobacco, or that otherwise incorporate tobacco, and are intended for human consumption. In particular, the disclosure relates to compositions or formulations incorporating tobacco, and that are intended to be employed in a smokeless form.

BACKGROUND OF THE DISCLOSURE

Cigarettes, cigars, and pipes are popular smoking articles that employ tobacco in various forms. Such smoking articles are employed by heating or burning tobacco to generate aerosol (e.g., smoke) that may be inhaled by the smoker. Tobacco may also be enjoyed in a so-called “smokeless” form. Particularly popular smokeless tobacco products are employed by inserting some form of processed tobacco or tobacco-containing formulation into the mouth of the user. See for example, the types of smokeless tobacco formulations, ingredients, and processing methodologies set forth in U.S. Pat. No. 1,376,586 to Schwartz; U.S. Pat. No. 3,696,917 to Levi; U.S. Pat. No. 4,513,756 to Pittman et al.; U.S. Pat. No. 4,528,993 to Sensabaugh, Jr. et al.; U.S. Pat. No. 4,624,269 to Story et al.; U.S. Pat. No. 4,991,599 to Tibbetts; U.S. Pat. No. 4,987,907 to Townsend; U.S. Pat. No. 5,092,352 to Sprinkle, III et al.; U.S. Pat. No. 5,387,416 to White et al.; U.S. Pat. No. 6,668,839 to Williams; U.S. Pat. No. 6,834,654 to Williams; U.S. Pat. No. 6,953,040 to Atchley et al.; U.S. Pat. No. 7,032,601 to Atchley et al.; and U.S. Pat. No. 7,694,686 to Atchley et al.; US Pat. Pub. Nos. 2004/0020503 to Williams; 2005/0115580 to Quinter et al.; 2005/0244521 to Strickland et al.; 2006/0191548 to Strickland et al.; 2007/0062549 to Holton, Jr. et al.; 2007/0186941 to Holton, Jr. et al.; 2007/0186942 to Strickland et al.; 2008/0029110 to Dube et al.; 2008/0029116 to Robinson et al.; 2008/0029117 to Mua et al.; 2008/0173317 to Robinson et al.; 2008/0196730 to Engstrom et al.; 2008/0209586 to Neilsen et al.; 2008/0305216 to Crawford et al.; 2009/0065013 to Essen et al.; 2009/0293889 to Kumar et al.; 2010/0291245 to Gao et al.; and 2011/0139164 to Mua et al.; PCT WO 2004/095959 to Arnarp et al.; and WO 2010/132444 A2 to Atchley; each of which is incorporated herein by reference. Exemplary smokeless tobacco products that have been marketed include those referred to as CAMEL Snus, CAMEL Orbs, CAMEL Strips and CAMEL Sticks by R. J. Reynolds Tobacco Company; GRIZZLY moist tobacco, KODIAK moist tobacco, LEVI GARRETT loose tobacco and TAYLOR'S PRIDE loose tobacco by American Snuff Company, LLC; KAYAK moist snuff and CHATTANOOGA CHEW chewing tobacco by Swisher International, Inc.; REDMAN chewing tobacco by Pinkerton Tobacco Co. LP; COPENHAGEN moist tobacco, COPENHAGEN Pouches, SKOAL Bandits, SKOAL Pouches, RED SEAL long cut and REVEL Mint Tobacco Packs by U.S. Smokeless Tobacco Company; and MARLBORO Snus and Taboka by Philip Morris USA.

It would be desirable to provide an enjoyable form of a tobacco product, such as a smokeless tobacco product.

SUMMARY OF THE DISCLOSURE

The present disclosure relates to a smokeless tobacco product configured for insertion into the mouth of a user and processes for preparing a smokeless tobacco composition suitable for use in a smokeless tobacco product. The smokeless tobacco composition incorporates a pectin component derived from tobacco or a tobacco material. Various properties can be imparted to the tobacco product by the tobacco-derived pectin material and such properties can be impacted, for example, by selection of the pectin source (e.g., which part or parts of the tobacco material is used), the techniques used to extract and isolate the pectin, and by any intentional or unintentional modification of the pectin structure.

The tobacco-derived pectin can provide various attributes to the smokeless tobacco product. For example, the pectin may provide some degree of integrity to the smokeless tobacco product. In use, the smokeless tobacco product may, in certain embodiments, be held together in whole or in part by the pectin component. Further, incorporation of tobacco-derived pectin within a smokeless tobacco product can give a product having a higher content of tobacco-derived components.

In one aspect of the invention is provided a smokeless tobacco product configured for insertion into the mouth of a user, the smokeless tobacco product comprising a tobacco material and a binder component, the binder component comprising a tobacco-derived pectin material in an amount of at least about 2% by weight, based on the total dry weight of the smokeless tobacco product. In certain embodiments, the tobacco-derived pectin material is the only binder component therein.

In some embodiments, the smokeless tobacco product can be extruded. The smokeless tobacco product can be, for example, in the form of a pill, pellet, tablet, coin, bead, ovoid, obloid, cube, film, flake, stick, foam, or gel. In some embodiments, the smokeless tobacco product is dissolvable.

The amount of tobacco-derived pectin can vary. For example, in certain embodiments, the smokeless tobacco product comprises greater than about 3% by weight of the tobacco-derived pectin material or greater than about 4% by weight of tobacco-derived pectin material. Various other components can be incorporated within the smokeless tobacco products of the present invention. For example, in some embodiments, the smokeless tobacco product further comprises one or more components selected from the group consisting of flavorants, sweeteners, salts, fillers, fats, emulsifiers, gelling agents, disintegration aids, compressability aids, colorants, humectants, pH adjusters, buffering agents, oral care additives, preservatives, syrups, and mixtures thereof. In certain embodiments, the tobacco material is in particulate form with an average particle size of less than about 50 microns.

In on embodiment, the invention provides a smokeless tobacco product comprising a tobacco material (e.g., a milled tobacco material or an aqueous tobacco extract) in an amount of about 20 to about 50 dry weight percent; a tobacco-derived pectin material in an amount of about 2 to about 10 dry weight percent; one or more fillers (e.g., at least one rice-derived filler material) in an amount of about 10 to about 40 dry weight percent; one or more sweeteners (e.g., at least one sugar alcohol) in any amount of about 5 to about 15 dry weight percent; and at least one flavorant in an amount up to about 5 dry weight percent. The product may further include an additional binder component, such as a natural gum.

In another aspect of the invention is provided a method of preparing a smokeless tobacco product, comprising: extracting pectin from a tobacco material to form a tobacco-derived pectin material; combining the tobacco-derived pectin material with a second tobacco material to form a smokeless tobacco composition; and incorporating the resulting composition into a smokeless tobacco product (e.g., by forming the composition into a desired product shape such as by extrusion), wherein the tobacco-derived pectin material is present in an amount of at least about 2% by dry weight of the smokeless tobacco product. In some embodiments, the tobacco-derived pectin material is present in an amount of at least about 3% by dry weight of the smokeless tobacco product or at least about 4% by dry weight of the smokeless tobacco product.

In some embodiments, the extracting step comprises mixing a cured tobacco material with an aqueous solution of oxalic acid and/or ammonium oxalate and collecting an aqueous extract. In certain embodiments, the extracting step further comprises adding a second solvent to the aqueous extract to effect precipitation of a pectin material and collecting the precipitated pectin material.

In a further aspect of the invention is provided a method for extracting pectin. In some embodiments, the method comprises mixing a cured tobacco material with an aqueous solution of oxalic acid and/or ammonium oxalate and collecting an aqueous extract. In certain embodiments, the method further comprises combining the extracted pectin with a second tobacco material to produce a smokeless tobacco product.

DETAILED DESCRIPTION

The present disclosure now will be described more fully hereinafter. The disclosure may be embodied in many different forms and should not be construed as limited to the aspects set forth herein; rather, these aspects are provided so that this disclosure will satisfy applicable legal requirements. As used in this specification and the claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.

In various embodiments, the present invention can provide smokeless tobacco compositions suitable for oral use. The smokeless tobacco compositions generally include a tobacco material, one or more pectin components, and optionally one or more additional components as described herein. In certain embodiments, at least one pectin component is derived from tobacco.

The products of the disclosure incorporate some form of a plant of the Nicotiana species, and most preferably, those compositions or products incorporate some form of tobacco. The selection of the Nicotiana species can vary; and in particular, the selection of the types of tobacco or tobaccos may vary. Tobaccos that can be employed include flue-cured or Virginia (e.g., K326), burley, sun-cured (e.g., Indian Kurnool and Oriental tobaccos, including Katerini, Prelip, Komotini, Xanthi and Yambol tobaccos), Maryland, dark, dark-fired, dark air cured (e.g., Passanda, Cubano, Jatin and Bezuki tobaccos), light air cured (e.g., North Wisconsin and Galpao tobaccos), Indian air cured, Red Russian and Rustica tobaccos, as well as various other rare or specialty tobaccos. Descriptions of various types of tobaccos, growing practices and harvesting practices are set forth in Tobacco Production, Chemistry and Technology, Davis et al. (Eds.) (1999), which is incorporated herein by reference. Various representative other types of plants from the Nicotiana species are set forth in Goodspeed, The Genus Nicotiana, (Chonica Botanica) (1954); U.S. Pat. No. 4,660,577 to Sensabaugh, Jr. et al.; U.S. Pat. No. 5,387,416 to White et al. and U.S. Pat. No. 7,025,066 to Lawson et al.; US Patent Appl. Pub. Nos. 2006/0037623 to Lawrence, Jr. and 2008/0245377 to Marshall et al.; each of which is incorporated herein by reference. Exemplary Nicotiana species include N. tabacum, N. rustica, N. alata, N. arentsii, N. excelsior, N. forgetiana, N. glauca, N. glutinosa, N. gossei, N. kawakamii, N. knightiana, N. langsdorffi, N. otophora, N. setchelli, N. sylvestris, N. tomentosa, N. tomentosiformis, N. undulata, N. x sanderae, N. africana, N. amplexicaulis, N. benavidesii, N. bonariensis, N. debneyi, N. longiflora, N. maritina, N. megalosiphon, N. occidentalis, N. paniculata, N. plumbaginifolia, N raimondii, N. rosulata, N. simulans, N. stocktonii, N. suaveolens, N. umbratica, N. velutina, N. wigandioides, N. acaulis, N. acuminata, N. attenuata, N. benthamiana, N. cavicola, N. clevelandii, N. cordifolia, N. corymbosa, N. fragrans, N. goodspeedii, N. linearis, N. miersii, N. nudicaulis, N. obtusifolia, N. occidentalis subsp. Hersperis, N. pauciflora, N. petunioides, N. quadrivalvis, N. repanda, N. rotundifolia, N. solanifolia, and N. spegazzinii.

Nicotiana species can be derived using genetic-modification or crossbreeding techniques (e.g., tobacco plants can be genetically engineered or crossbred to increase or decrease production of components, characteristics or attributes). See, for example, the types of genetic modifications of plants set forth in U.S. Pat. No. 5,539,093 to Fitzmaurice et al.; U.S. Pat. No. 5,668,295 to Wahab et al.; U.S. Pat. No. 5,705,624 to Fitzmaurice et al.; U.S. Pat. No. 5,844,119 to Weigl; U.S. Pat. No. 6,730,832 to Dominguez et al.; U.S. Pat. No. 7,173,170 to Liu et al.; U.S. Pat. No. 7,208,659 to Colliver et al. and U.S. Pat. No. 7,230,160 to Benning et al.; US Patent Appl. Pub. No. 2006/0236434 to Conkling et al.; and PCT WO 2008/103935 to Nielsen et al.

For the preparation of smokeless and smokable tobacco products, it is typical for a harvested plant of the Nicotiana species to be subjected to a curing process. Descriptions of various types of curing processes for various types of tobaccos are set forth in Tobacco Production, Chemistry and Technology, Davis et al. (Eds.) (1999). Exemplary techniques and conditions for curing flue-cured tobacco are set forth in Nestor et al., Beitrage Tabakforsch. Int., 20, 467-475 (2003) and U.S. Pat. No. 6,895,974 to Peele, which are incorporated herein by reference. Representative techniques and conditions for air curing tobacco are set forth in U.S. Pat. No. 7,650,892 to Groves et al.; Roton et al., Beitrage Tabakforsch. Int., 21, 305-320 (2005) and Staaf et al., Beitrage Tabakforsch. Int., 21, 321-330 (2005), which are incorporated herein by reference. Certain types of tobaccos can be subjected to alternative types of curing processes, such as fire curing or sun curing. Preferably, harvested tobaccos that are cured are then aged. As such, tobaccos used for the preparation of tobacco compositions or products most preferably incorporate components of tobaccos that have been cured and aged. Tobacco materials used in the present invention can be subjected to additional processing prior to use, such as fermentation, bleaching, and the like.

At least a portion of the plant of the Nicotiana species (e.g., at least a portion of the tobacco portion) can be employed in an immature form. That is, the plant, or at least one portion of that plant, can be harvested before reaching a stage normally regarded as ripe or mature. As such, for example, tobacco can be harvested when the tobacco plant is at the point of a sprout, is commencing leaf formation, is commencing flowering, or the like.

At least a portion of the plant of the Nicotiana species (e.g., at least a portion of the tobacco portion) can be employed in a mature form. That is, the plant, or at least one portion of that plant, can be harvested when that plant (or plant portion) reaches a point that is traditionally viewed as being ripe, over-ripe or mature. As such, for example, through the use of tobacco harvesting techniques conventionally employed by farmers, Oriental tobacco plants can be harvested, burley tobacco plants can be harvested, or Virginia tobacco leaves can be harvested or primed by stalk position.

After harvest, the plant of the Nicotiana species, or portion thereof, can be used in a green form (e.g., tobacco can be used without being subjected to any curing process). For example, tobacco in green form can be frozen, subjected to irradiation, yellowed, dried, cooked (e.g., roasted, fried or boiled), or otherwise subjected to storage or treatment for later use. Such tobacco also can be subjected to aging conditions. However, as noted above, it is preferred according to the present invention for the tobacco to be cured and aged.

The tobacco material may be cased and dried, and then ground to the desired form. For example, in some instances, the tobacco material formulation may be cased with an aqueous casing containing components such as sugars (e.g., fructose, glucose, and sucrose), humectants (e.g., glycerin and propylene glycol), flavoring ingredients (e.g., cocoa and licorice), and the like. Non-aqueous casing components may be applied to the tobacco in amounts of about 1 percent to about 15 percent, based on the dry weight of the tobacco.

The tobacco material is typically used in a form that can be described as particulate (i.e., shredded, ground, granulated, or powder form). The manner by which the tobacco material is provided in a finely divided or powder type of form may vary. Preferably, plant parts or pieces are comminuted, ground or pulverized into a particulate form using equipment and techniques for grinding, milling, or the like. Most preferably, the plant material is relatively dry in form during grinding or milling, using equipment such as hammer mills, cutter heads, air control mills, or the like. For example, tobacco parts or pieces may be ground or milled when the moisture content thereof is less than about 15 weight percent or less than about 5 weight percent. Most preferably, the tobacco material is employed in the form of parts or pieces that have an average particle size less than about 50 microns. In one embodiment, the average particle size of the tobacco particles may be less than or equal to about 25 microns. In some instances, the tobacco particles may be sized to pass through a screen mesh. If desired, air classification equipment may be used to ensure that small sized tobacco particles of the desired sizes, or range of sizes, may be collected. If desired, differently sized pieces of granulated tobacco may be mixed together.

At least a portion of the tobacco material employed in the tobacco composition or product (e.g., the tobacco component) can have the form of an extract. Tobacco extracts can be obtained by extracting tobacco using a solvent having an aqueous character such as distilled water or tap water. As such, aqueous tobacco extracts can be provided by extracting tobacco with water, such that water insoluble pulp material is separated from the aqueous solvent and the water soluble and dispersible tobacco components dissolved and dispersed therein. The tobacco extract can be employed in a variety of forms. For example, the aqueous tobacco extract can be isolated in an essentially solvent free form, such as can be obtained as a result of the use of a spray drying or freeze drying process, or other similar types of processing steps. Alternatively, the aqueous tobacco extract can be employed in a liquid form, and as such, the content of tobacco solubles within the liquid solvent can be controlled by selection of the amount of solvent employed for extraction, concentration of the liquid tobacco extract by removal of solvent, addition of solvent to dilute the liquid tobacco extract, or the like. Exemplary techniques for extracting components of tobacco are described in U.S. Pat. No. 4,144,895 to Fiore; U.S. Pat. No. 4,150,677 to Osborne, Jr. et al.; U.S. Pat. No. 4,267,847 to Reid; U.S. Pat. No. 4,289,147 to Wildman et al.; U.S. Pat. No. 4,351,346 to Brummer et al.; U.S. Pat. No. 4,359,059 to Brummer et al.; U.S. Pat. No. 4,506,682 to Muller; U.S. Pat. No. 4,589,428 to Keritsis; U.S. Pat. No. 4,605,016 to Soga et al.; U.S. Pat. No. 4,716,911 to Poulose et al.; U.S. Pat. No. 4,727,889 to Niven, Jr. et al.; U.S. Pat. No. 4,887,618 to Bernasek et al.; U.S. Pat. No. 4,941,484 to Clapp et al.; U.S. Pat. No. 4,967,771 to Fagg et al.; U.S. Pat. No. 4,986,286 to Roberts et al.; U.S. Pat. No. 5,005,593 to Fagg et al.; U.S. Pat. No. 5,018,540 to Grubbs et al.; U.S. Pat. No. 5,060,669 to White et al.; U.S. Pat. No. 5,065,775 to Fagg; U.S. Pat. No. 5,074,319 to White et al.; U.S. Pat. No. 5,099,862 to White et al.; U.S. Pat. No. 5,121,757 to White et al.; U.S. Pat. No. 5,131,414 to Fagg; U.S. Pat. No. 5,131,415 to Munoz et al.; U.S. Pat. No. 5,148,819 to Fagg; U.S. Pat. No. 5,197,494 to Kramer; U.S. Pat. No. 5,230,354 to Smith et al.; U.S. Pat. No. 5,234,008 to Fagg; U.S. Pat. No. 5,243,999 to Smith; U.S. Pat. No. 5,301,694 to Raymond et al.; U.S. Pat. No. 5,318,050 to Gonzalez-Parra et al.; U.S. Pat. No. 5,343,879 to Teague; U.S. Pat. No. 5,360,022 to Newton; U.S. Pat. No. 5,435,325 to Clapp et al.; U.S. Pat. No. 5,445,169 to Brinkley et al.; U.S. Pat. No. 6,131,584 to Lauterbach; U.S. Pat. No. 6,284,875 to Turpen et al.; U.S. Pat. No. 6,298,859 to Kierulff et al.; U.S. Pat. No. 6,772,767 to Mua et al.; U.S. Pat. No. 6,817,970 to Berit et al.; U.S. Pat. No. 6,906,172 to Bratcher et al.; U.S. Pat. No. 7,034,128 to Turpen et al.; U.S. Pat. No. 7,048,211 to Bratcher et al.; and U.S. Pat. No. 7,337,782 to Thompson, all of which are incorporated by reference herein.

The relative amount of tobacco material within the smokeless tobacco composition may vary. Preferably, the amount of tobacco material within the smokeless tobacco composition is at least about 10 percent or at least about 20 percent, on a dry weight basis of the composition, and including all sources of tobacco including tobacco components and any tobacco-derived components such as binders. In certain instances, the amounts of other components within the smokeless tobacco composition may exceed about 40 percent, on a dry weight basis. A typical range of tobacco material within the smokeless tobacco composition is about 20 to about 50 dry weight percent. The tobacco material may, in certain embodiments, be subjected to thermal or convection heating to control the moisture content thereof prior to incorporating it within a smokeless tobacco product according to the present invention. As a specific example, the tobacco material formulation may be oven-dried, in warmed air at temperatures of about 40° C. to about 95° C. for a length of time appropriate to attain the desired moisture content. For example, the tobacco material formulation may be dried for about 12 hours to about 24 hours at about 54° C. to about 60° C.

In some instances, prior to preparation of the tobacco material formulation, the tobacco parts or pieces may be irradiated, or those parts and pieces may be pasteurized, or otherwise subjected to controlled heat treatment. Additionally, if desired, after preparation of all or a portion of the tobacco material formulation, the component materials may be irradiated, or those component materials may be pasteurized, or otherwise subjected to controlled heat treatment. For example, a tobacco material formulation may be prepared, followed by irradiation or pasteurization, and then flavoring ingredient(s) may be applied to the formulation. Representative processes are set forth in US Pat. Pub. Nos. 2009/0025738 to Mua et al; 2009/0025739 to Brinkley et al.; and 2011/0247640 to Beeson et al., which are incorporated herein by reference.

In addition to the aforementioned tobacco component, the smokeless tobacco products of the present invention comprise a binder component that includes pectin. Generally, the term “pectin” refers to a complex group of polysaccharides principally comprising 1,4-linked α-D-galactosyluronic acid residues. Typically, pectin comprises at least about 65% such subunits. The acid groups present on these residues can be free acids, combined as a methyl ester, or in salt form (e.g., as sodium, potassium, calcium, or ammonium salts). The molecular weight of pectin can vary; for example, the number average molecular weight can be from about 60 Da to about 13,0000 Da, and can vary based on origin and extraction conditions.

Certain pectic polysaccharides include polygalacturonan (comprising linear galacturonic acid subunits), rhamnogalacturonan I (RG1, comprising alternating rhamnose and galacturonic acid subunits), and rhamnogalacturonan II (RG2, a complex, highly branched polysaccharide). Pectin is often characterized in terms of its “hairy” and “smooth” regions. Hairy regions of pectin are portions of the molecule that are very flexible and which may comprise many neutral sugar molecules, such as rhamnose, galactose, arabinose, and/or other sugars, in a highly branched structure. Smooth regions of pectin are portions of the molecule that comprise primarily homogalacturonic acid.

Pectin is found in most plants, for example, in the cell walls (where the pectin acts as a binder to hold the cell walls together). The amount and characteristics of pectin in different plants can vary significantly. Further, even within the same plant, pectin from different tissues of the plant and pectin present in the plant at different stages of development can exhibit different characteristics. For example, the arrangement and amounts of various monosaccharide derivative units, the degree of esterification, and the polymer lengths of the heteropolysaccharides can vary significantly.

The structure and characteristics of pectin within a given pectin sample can depend on the extraction method. For example, commercial extraction of pectin often causes extensive degradation of the neutral sugar-containing sidechains of the polysaccharide. In other words, most extraction methods result in the destruction of many of the hairy regions of the pectin, leaving mainly smooth galacturonic acid regions, with only a few neutral sugar units attached to and/or in the main linear chain. These neutral sugar units remaining can vary in nature and location on the pectin chain and can influence the properties of pectin.

A given sample of pectin can comprise some degree of pectin derivatives. Such pectin derivatives can be naturally occurring in the pectin sample or the sample can be treated in some way to promote formation of one or more pectin derivatives. Pectin derivatives include, but are not limited to, protopectin, pectinic acid, esterified pectin, wherein one or more carboxylic acid groups are methylated, pectin salts, and/or pectic acid. Esterification is common, and the degree of esterification typically determines the degree of reactivity of the pectin or derivative thereof with calcium and other cations. Pectin as extracted generally has greater than about 50% of its acidic functionalities esterified, and is thus sometimes classified as “high methyl ester (HM) pectin.” Modification of the extraction process (e.g., extended hydrolysis) or continued acid treatment will typically give a “low methyl ester (LM) pectin,” with less than about 50% methyl ester groups. Pectin can be treated, in some embodiments, during and/or following extraction and isolation of the pectin to alter the degree of esterification. For example, in certain embodiments, controlled removal of methoxy groups (i.e., de-esterification) is done to convert HM pectin to LM pectin. This conversion can be accomplished, for example, with pectin methylesterases and/or via extended hydrolysis. Some pectins are treated during manufacture with ammonia to produce amidated pectins. Some pectins are partially or completely converted to salts (e.g., by modifying the carboxyl groups of the D-galactopyranosyluronic acid residues).

According to the present invention, smokeless tobacco products can advantageously comprise pectin derived from tobacco. As used herein, the term “tobacco-derived pectin,” refers to a pectin material extracted or isolated from a tobacco plant or portion thereof, and such material is understood to have a variable level of purity with respect to pectin and, accordingly, can include other components extracted or isolated from tobacco in addition to pectin. The method by which pectin is derived from a tobacco material can vary. The pectin can be derived from any part of a tobacco plant or portion thereof (e.g., leaves, seeds, flowers, stalks, roots, and/or stems). Although the tobacco material can vary, in certain embodiments, the pectin is derived from tobacco lamina and/or stem. Pectin from various locations of the tobacco plant can be kept separate, or pectin from various locations within the tobacco plant can be combined and processed and/or used in combination according to the present invention. In some embodiments, the tobacco material is cured prior to the process of isolating the pectin therefrom.

Advantageously, tobacco is treated so as to provide the pectin contained therein in a more usable (e.g., more concentrated) form. The pectin can be isolated from tobacco or tobacco materials using any suitable method. Typically, one or more extraction processes are used to first isolate the pectin into an extraction solvent. For example, in some embodiments, tobacco or a tobacco material is first extracted (e.g., with water or an aqueous solution of one or more reagents). The temperature of the water and the time for which the tobacco or tobacco material remains in contact with the water can vary. In some embodiments, the mixture is heated. For example, it may be heated to about 50° C., about 75° C., or about 100° C. In some embodiments, the mixture is agitated. The pH of the solution can vary, but in certain embodiments, the extraction solvent is acidic.

Various reagents can be added to the extraction solvent. In some embodiments, a processing aid is added to facilitate the extraction. A processing aid is any agent that facilitates the extraction of the pectin into the extraction solvent. For example, suitable processing aids include, but are not limited to, mineral acids and enzymes. The processing aid selected can affect the structure of the pectin; for example, use of enzymes typically results in shorter, branched segments. Various other additives can be used in the extraction process, including, but not limited to, surfactants and co-solvents. In certain embodiments, oxalic acid and/or ammonium oxalate (i.e., oxalic acid or a salt thereof) are added to the mixture. As noted above, the extraction conditions and the amount of time for which the tobacco remains in contact with the extraction solvent can impact the properties of the pectin (e.g., the degree of esterification).

After the extraction process, the remaining solids are typically separated and the resulting solution is clarified. The separation of solids from solution and clarification can be accomplished via various methods as described herein (e.g., filtration, including ultrafiltration, centrifugation, and/or distillation) to give an extract. In certain embodiments, multiple clarification steps are conducted. In some embodiments, the extracted mixture is concentrated. Concentration can occur before and/or after the separation of solids, but is commonly done after the separation of solids.

The extract is typically further processed to further isolate the pectin from other compounds present in the extract. In some embodiments, the pectin can be precipitated from the clarified solution. For example, one means by which the pectin can be precipitated is to mix the concentrated solution with a reagent to precipitate the pectin, including, but not limited to, alcohol (e.g., ethanol and/or isopropanol), protein-containing solution, and/or detergent-containing solution. Where the pectin sample is converted in whole or in part to one or more pectin derivatives, the derivatives may precipitate readily from the clarified solution without the addition of any reagent, or may require the addition of one or more reagent to ensure the precipitation of pectin and various pectin derivatives that may be present in a given sample. The precipitation may be conducted at reduced temperatures. For example, the mixture may be cooled to around 0° C. (e.g., around 5° C.) to promote precipitation of the pectin. The resulting solid precipitate is then separated from the solution (e.g., by filtration or centrifugation). The precipitate is then commonly washed and dried.

The purity of the tobacco-derived pectin can vary, although it is preferably relatively high. Purity as intended herein refers to the content of both pectin and pectin derivatives as described above. For example, the tobacco-derived pectin sample is typically at least about 50% pure, at least about 60% pure, at least about 70% pure, at least about 80% pure, at least about 85% pure, at least about 90% pure, at least about 95% pure, at least about 98% pure, or at least about 99% pure. In certain embodiments, the pectin comprises less than about 20% non-tobacco-derived material, less than about 15% non-tobacco-derived material, less than about 10% non-tobacco-derived material, less than about 5% non-tobacco-derived material, less than about 2% non-tobacco derived material, less than about 1% non-tobacco-derived material, or less than about 0.5% non-tobacco derived material.

In certain embodiments, various agents can be added at certain stages in the extraction and/or isolation processes to modify the pectin. As noted above, the present invention is intended to cover not only the isolation and use of pure pectin derived from tobacco, but also pectin derivatives produced therefrom, either naturally or synthetically. For example, the pectin-containing precipitate described above can be washed with a salt-containing or alkali-containing solvent to convert pectin in part or in whole to salt form. In some embodiments, the precipitate is treated with ammonia to produce some degree of amidated pectin.

Other methods for the extraction of pectin from tobacco or tobacco materials can be utilized according to the invention. For example, Zhao et al. have reported on methods for extraction of pectin from tobacco stem, in Modern Agric. Sci. Tech., 2010-01, which is incorporated herein by reference. Rao et al. have highlighted other extraction methods in Guangzhou Chem.; 2009-01, which is also incorporated herein by reference. Other methods for extraction of pectin can be found, for example, in U.S. Pat. Nos. 3,353,541 and 3,420,241 to Hind and Seligman; U.S. Pat. No. 3,760,815 to Deszyck, and U.S. Pat. No. 4,674,519 to Keritsis et al., and US Pat. Appl. Publ. No. 2011/0061666 to Dube, which are all incorporated herein by reference. In certain embodiments, pectin is extracted as taught by U.S. patent aplpication Ser. No. 13/072,019 to Morton et al., filed Mar. 25, 2011, which is incorporated herein by reference, wherein pectin is extracted by means of a pectin extraction apparatus in which a dried plant pulp component is contacted with an extraction buffer (e.g., a solution of about 10% acetic acid and about 10 mM ethylenediaminetetraacetic acid (EDTA)), and the separated extract is precipitated by the addition of ethanol. In some embodiments, fine tobacco powder is cooked in an alkaline pH adjusted solution at elevated temperatures relative to ambient to release pectin, which can subsequently be separated and/or used according to the invention. Such treatment also can provide desirable sensory attributes to the tobacco material. See, for example, U.S. Pat. Nos. 5,099,864 to Young et al.; U.S. Pat. No. 5,339,838 to Young et al.; and U.S. Pat. No. 5,501,237 to Young et al., which are incorporated herein by reference.

In some embodiments, tobacco or a tobacco material (e.g., tobacco shreds, scraps, dust, or fines) is treated prior to extraction to effectuate the release of pectins. As taught by U.S. Pat. No. 3,746,012 to Desczyk, which is incorporated herein by reference, pectins in tobacco often comprise protopectins, comprising calcium and magnesium salts of partially esterified and acetylated polymers of galacturonic acid. Accordingly, it may be desirable to treat such materials with a reagent such as an alkali metal carbonate, with a chelating agent (e.g., EDTA), or with an acid (e.g., HCl, phosphoric acid) to break the protopectin crosslinks and release the tobacco pectins. Other pectin releasing agents are also intended to be encompassed within the methods of the invention. For example, diammonium hydrogen phosphate (DAP) has been noted to be effective in small amounts, and generally does not affect the pectin in any noticeable way.

The form of the pectin derived from the tobacco or tobacco material and used in smokeless tobacco products can vary. In some embodiments, the tobacco-derived pectin is used in dried solid form directly as produced by the extraction process. In other embodiments, the dried solid is ground into a powder or granules of varying particle size. The pectin component, when provided in a powder or granulated form, is typically employed in the form of parts or pieces that have an average particle size less than about 50 microns. According to some aspects, the average particle size of the pectin component may be about 25 microns or less. In some embodiments, the pectin is used in solution. In certain embodiments, the pectin component is admixed with one or more other components of the smokeless tobacco product before being combined with the remaining ingredients to make up the smokeless tobacco products of the invention.

The tobacco-derived pectin can provide various functions within the smokeless tobacco products of the present invention. Pectin is commonly used as a gelling agent and thus can perform thickening, binding, and/or stabilizing functions within the smokeless tobacco products. For example, the tobacco-derived pectin can act as a binder. A binder generally acts to help maintain the form and/or structure of a material. In some embodiments, a binder may help to facilitate the formation of a tobacco-containing product into the desired form. In some embodiments, it may provide a level of structural integrity to the formed product. The tobacco-derived pectin may be added in addition to one or more other binders, or may be used as the sole binder. In some embodiments, it may be useful as a binder for certain reconstituted tobacco compositions.

It is noted herein that various tobacco compositions have incorporated pectin (including tobacco-derived pectin). For example, pectin has been incorporated as a binder within an insulating material for a fuel element of a smoking article with conductive aerosol chamber, as described in U.S. Pat. No. 5,105,831 to Banerjee et al., which is incorporated herein by reference. Various pectin-containing reconstituted tobacco materials have been developed, and are described for example, in U.S. Pat. No. 3,386,449 to Hind; U.S. Pat. No. 3,420,241 to Hind et al.; U.S. Pat. No. 3,529,602 to Hind et al.; U.S. Pat. No. 3,353,541 to Hind et al.; U.S. Pat. No. 3,760,815 to Deszyck; U.S. Pat. No. 4,674,519 to Keritsis; and U.S. Pat. Nos. 5,099,864; 5,339,838; and 5,501,237 to Young et al., which are incorporated herein by reference. Pectin can also be used as a source of dietary fiber.

In certain embodiments, the tobacco-derived pectin provided herein is sufficient to fulfill the intended function of a binder in smokeless tobacco products. For example, the tobacco-derived pectin may be, and is preferably sufficient to provide a cohesive tobacco composition. For example, the tobacco-derived pectin may function to hold the smokeless tobacco product together in use. In certain embodiments, the tobacco-derived pectin provides a degree of structural integrity in a solid tobacco composition. In a film-based smokeless tobacco composition, the tobacco-derived pectin may provide some level of film-forming capability or control. However, in certain embodiments, one or more additional binders (e.g., povidone, sodium carboxymethylcellulose and other modified cellulosic types of binders, sodium alginate, xanthan gum, starch-based binders, gum arabic, gellan gum, lecithin, and the like), can be added according to the invention to afford the desired product characteristics. The use of natural tobacco pectin can act to reduce the amount of additional gums/hydrocolloids, cellulose-derived, or starch-based binders needed to aid in desired sheet or film tensile strength qualities.

The tobacco-derived pectin binder (or combination of binders) may be employed in amounts sufficient to provide the desired physical attributes and physical integrity to the smokeless tobacco composition. For example, the smokeless tobacco composition can comprise greater than about 1%, greater than about 2%, greater than about 3%, greater than about 4%, greater than about 5%, greater than about 6%, greater than about 7%, greater than about 8%, greater than about 9%, or greater than about 10% of tobacco-derived pectin, based on the total dry weight of the smokeless tobacco composition or product. A representative amount of binder may be between about 1% and about 25% tobacco-derived pectin by total dry weight of the smokeless tobacco product or between about 2% and about 20% tobacco-derived pectin by total dry weight of the smokeless tobacco product, or between about between about 3% and about 10% tobacco-derived pectin by total dry weight of the smokeless tobacco product. Preferably, the total amount of binder within the composition will not exceed about 45% of the total dry weight of the composition. Often, the amount of binder within a desirable composition will not exceed about 40%, and frequently will not exceed about 35 percent, about 25%, about 15%, or about 10% of the total dry weight of the composition. The smokeless tobacco product can comprise, for example, about 1% by weight, about 2% by weight, about 3% by weight, about 4% by weight, about 5% by weight, about 6% by weight, about 7% by weight, about 8% by weight, about 9% by weight, or about 10% by weight of tobacco-derived pectin.

In certain embodiments, the one or more additional binders, where employed in the smokeless tobacco products of the invention, include a natural gum. As used herein, a natural gum refers to polysaccharide materials of natural origin that are useful as thickening or gelling agents. Representative natural gums derived from plants, which are typically water soluble to some degree, include xanthan gum, guar gum, gum arabic, ghatti gum, gum tragacanth, karaya gum, locust bean gum, gellan gum, and combinations thereof.

The use of tobacco-derived pectin can afford a smokeless tobacco product having a higher degree of tobacco-derived components. Replacing and/or supplementing traditional binders with tobacco-derived pectin in smokeless tobacco products can, in some embodiments, provide the smokeless tobacco product with various characteristics, some of which are improved over those of smokeless tobacco products employing traditional binders. For example, in some embodiments, smokeless tobacco products employing tobacco-derived pectin exhibit increased rigidity over smokeless tobacco products employing traditional binders. Increased rigidity can, in some embodiments, be quantified. However, in some embodiments, the increased rigidity is simply evaluated by feel of the product (e.g., by trying to bend/flex the product). In some embodiments, smokeless tobacco products employing tobacco-derived pectin exhibit reduced tackiness as compared to smokeless tobacco products employing traditional binders. The reduction in tackiness can, in some embodiments, be quantified. In some embodiments, the reduction in tackiness is simply evaluated by feel of the product. In certain specific embodiments, smokeless tobacco products comprising tobacco-derived pectin as a binder rather than commercially available pullulan binder exhibit increased rigidity and/or reduced tackiness. Pullulan and smokable products incorporating pullulan are discussed in more detail for example, in US Pat. Pub. No. 2007/0137668 to Borschke et al., which is incorporated herein by reference.

The tobacco material and tobacco-derived pectin binder can be combined in any manner known in the art, such as by simply mixing the two components together using conventional mixing apparatuses. The tobacco material and tobacco-derived pectin ingredients can also be processed, blended, formulated, combined and mixed with other materials or ingredients. See, for example, those representative components, combination of components, relative amounts of those components and ingredients relative to tobacco, and manners and methods for employing those components, set forth in US Pat. Pub. Nos. 2007/0062549 and 2007/0186941 to Holton, et al., each of which is incorporated herein by reference.

The additional ingredients can be artificial, or can be obtained or derived from herbal or biological sources. Exemplary types of ingredients include salts (e.g., sodium chloride, potassium chloride, sodium citrate, potassium citrate, sodium acetate, potassium acetate, and the like), natural sweeteners (e.g., fructose, sucrose, glucose, maltose, vanillin, ethylvanillin glucoside, mannose, galactose, lactose, and the like), artificial sweeteners (e.g., sucralose, saccharin, aspartame, acesulfame K, neotame and the like), organic and inorganic fillers (e.g., grains, processed grains, puffed grains, maltodextrin, dextrose, calcium carbonate, calcium phosphate, corn starch, lactose, sugar alcohols such as isomalt, mannitol, xylitol, or sorbitol, finely divided cellulose, vegetable protein, and the like), gelling agents (e.g., fish gelatin), pH adjusters or buffering agents (e.g., metal hydroxides, preferably alkali metal hydroxides such as sodium hydroxide and potassium hydroxide, and other alkali metal buffers such as metal carbonates, preferably potassium carbonate or sodium carbonate, or metal bicarbonates such as sodium bicarbonate, and the like), emulsifiers, colorants (e.g., dyes and pigments, including caramel coloring, titanium dioxide, and the like), humectants (e.g., glycerin, propylene glycol, and the like), oral care additives (e.g., thyme oil, eucalyptus oil, and zinc), preservatives (e.g., potassium sorbate and the like), syrups (e.g., honey, high fructose corn syrup, and the like), disintegration or compressibility aids (e.g., microcrystalline cellulose, croscarmellose sodium, crospovidone, sodium starch glycolate, pregelatinized corn starch, and the like), flavorant and flavoring mixtures, antioxidants, and mixtures thereof. Exemplary types of additives may include those described in, for example, U.S. Pat. Pub. No. 2010/0291245 to Gao et al., previously incorporated by reference herein.

The sweetener component of the smokeless tobacco products of the present invention can be any sweetener, in natural or artificial form or as a combination of artificial and natural sweeteners. In one embodiment, sugar (i.e., sucrose) is the primary sweetener ingredient. In other embodiments, sucralose, maltodextrin, or corn syrup is the primary sweetener ingredient. In certain embodiments, both sucrose and corn syrup are used in the smokeless tobacco products. Other exemplary sweeteners are sugar alcohols. Sugar alcohols are polyols derived from monosaccharides or disaccharides that have a partially or fully hydrogenated form. Exemplary sugar alcohols have between about 4 and about 20 carbon atoms and include erythritol, arabitol, ribitol, isomalt, maltitol, dulcitol, iditol, mannitol, xylitol, lactitol, sorbitol, and combinations thereof (e.g., hydrogenated starch hydrolysates). When present, a representative amount of sweetener, whether an artificial sweetener and/or natural sugar or sugar alcohol, may make up at least about 5 percent, often at least about 10% and frequently at least about 15% of the total dry weight of the composition. Preferably, the amount of sweetener within the composition will not exceed about 40 percent, often will not exceed about 35 percent, and frequently will not exceed about 30 percent, of the total dry weight of the composition.

In certain embodiments, a syrup is employed in amounts sufficient to provide chewiness and retard solubilization, or otherwise provide desired flavor attributes to the smokeless tobacco composition. When present, a representative amount of syrup (e.g., corn syrup) may make up at least about 5%, often at least about 10%, and frequently at least about 20% of the total dry weight of the composition.

In some embodiments, the smokeless tobacco compositions of the disclosure also include at least one filler ingredient. In some embodiments, sugar alcohols are particularly advantageous as filler components in certain products of the disclosure because such materials contribute some sweetness and do not disrupt the chewable characteristics which may be desired in the final product. In some embodiments, a fondant filler is used. Fondant fillers typically comprise sugar, corn syrup, and water. One exemplary fondant filler composition consists of sugar, corn syrup, water, albumen, algin, citric acid, vanillin, sodium propionate, and potassium sorbate.

A filler component often fulfills multiple functions, such as enhancing certain organoleptic properties such as texture and mouthfeel, enhancing cohesiveness or compressibility of the product, and the like. When present, a representative amount of filler, whether an organic and/or inorganic filler, may make up at least about 1 percent, at least about 2 percent, or at least about 5 percent, based on the total dry weight of the composition. Preferably, the amount of filler within the composition will not exceed about 50 percent, often will not exceed about 40%, and frequently will not exceed about 30 percent of the total dry weight of the composition. In certain embodiments, the filler component includes one or more rice-derived fillers, such as rice starch or rice flour or combinations thereof.

In some embodiments, one or more fats are added. The fat may function, for example, as a processing aid and/or to optimize the appearance of the smokeless tobacco product. For example, pre-melted fat such as partially hydrogenated soybean oil can be included in the composition.

As used herein, a “flavorant” or “flavoring agent” is any flavorful or aromatic substance capable of altering the sensory characteristics associated with the smokeless tobacco composition. Exemplary sensory characteristics that can be modified by the flavorant include, taste, mouthfeel, moistness, coolness/heat, and/or fragrance/aroma. The flavorants can be natural or synthetic, and the character of these flavors can be described as, without limitation, fresh, sweet, herbal, confectionary, floral, fruity or spice. Specific types of flavors include, but are not limited to, vanilla, coffee, chocolate, cream, mint (e.g., mint oil), spearmint, menthol, peppermint, wintergreen, lavender, cardamon, nutmeg, cinnamon, clove, cascarilla, sandalwood, honey, jasmine, ginger, anise, sage, licorice, lemon, orange, apple, peach, lime, cherry, and strawberry. Flavorants utilized in the disclosure also can include components that are considered moistening, cooling or smoothening agents, such as eucalyptus. These flavors may be provided neat (i.e., alone) or in a composite (e.g., spearmint and menthol or orange and cinnamon). In some instances, the flavorant may be provided in a spray-dried form or a liquid form. Flavorants are typically present in an amount of about 0.5 to about 10 dry weight percent, often about 1 to about 6 dry weight percent, and most often about 2 to about 5 dry weight percent.

A salt (e.g., sodium chloride, flour salt) may be employed in amounts sufficient to provide desired sensory attributes to the smokeless tobacco composition. When present, a representative amount of salt is at least about 0.5 dry weight percent or at least about 1.0 dry weight percent or at least about 1.5 dry weight percent, but will typically may make up less than about 5 percent of the total dry weight of the composition (e.g., about 0.5 to about 4 dry weight percent).

A humectant (e.g., glycerin) may be employed in amounts sufficient to provide desired moisture attributes to the smokeless tobacco composition. Further, in some instances, the humectant may impart desirable flow characteristics to the smokeless tobacco composition for depositing in a starch mould. When present, a representative amount of humectant is at least about 0.5 dry weight percent or at least about 1.0 dry weight percent or at least about 1.5 dry weight percent, but will typically make up less than about 5 percent of the total dry weight of the composition (e.g., about 0.5 to about 4 dry weight percent).

Preferred buffering agents buffer within a pH range of about 6 to about 10, and exemplary buffering agents include metal hydroxides, metal carbonates, metal bicarbonates, or mixtures thereof. The buffering agent is typically present in an amount less than about 1 percent based on the dry weight of the formulation.

Such additional ingredients may be provided in a powder or granulated form for mixing with the tobacco material formulation, or otherwise may be provided in liquid form. Most preferably, the ingredients when provided in a powder or granulated form is employed in the form of parts or pieces that have an average particle size less than about 50 microns. According to some aspects, the average particle size of the additive may be about 25 microns or less. The moisture content of the additives provided in a powder or granulated form may vary. Most preferably, the moisture content of the additive provided in a powder or granulated form is less than about 10 weight percent, and may be less than about 5 percent, and is often less than about 2.5 weight percent. The additive may be admixed with any component or with the tobacco material in, for example, a Hobart mixer with a paddle prior to adding any liquid additives. In the event liquid additives are provided, the resultant mixture may still have a relatively low moisture content of less than about 10 weight percent, and may be less than about 5 percent, and is often less than about 2.5 weight percent. The relative amounts of the various additive components within the smokeless tobacco product may vary.

The aforementioned types of ingredients can be employed together (e.g., as ingredient formulations) or separately (e.g., individual additive components can be added at different stages involved in the preparation of the final tobacco product). The relative amounts of the various components within the smokeless tobacco formulation may vary, and typically are selected so as to provide the desired sensory and performance characteristics to the tobacco product. Furthermore, the aforementioned types of additives may be encapsulated as provided in the final product or composition. Exemplary encapsulated additives are described, for example, in WO 2010/132444 A2 to Atchley, which has been previously incorporated by reference herein.

Any of the above-noted classes of ingredients for the smokeless tobacco composition of the disclosure can be derived from tobacco material by subjecting at least a portion of a tobacco plant (e.g., leaves, seeds, flowers, stalks, roots, or stems) to a separation process, which typically can include multiple sequential extraction steps, in order to isolate desired components of the tobacco material. Exemplary separation processes include chromatography, distillation, filtration, recrystallization, solvent-solvent partitioning, cold pressing, solvent extraction (e.g., using solvents such as water, alcohols or hydrocarbons such as heptane or hexane), or a combination thereof. The resulting isolated tobacco component can be chemically transformed prior to use in the compositions of the disclosure. Exemplary chemical transformations include hydrogenation, esterification, transesterification, isomeric conversion, acetal formation, acetal decomposition, acid/base reaction, hydrolysis, thermal treatment, enzymatic treatment, and combinations of such steps. Techniques for preparing tobacco isolates for use in the compositions of the disclosure are set forth, for example, in U.S. Pat. Pub. Nos. 2011/0174323 to Coleman, III et al., and U.S. application Ser. No. 12/764,613 to Coleman, III et al., filed Apr. 21, 2010, which are incorporated by reference herein in their entirety. Examples of the types of compounds that may be present in the tobacco isolate include hydrocarbons, cellulose, alcohols, aldehydes, ketones, carboxylic acids, amino acids, esters, lactones, anhydrides, carbohydrates (e.g., reducing sugars), phenols, quinones, ethers, nitriles, amines, amides, imides, plastid pigments, proteins, coenzyme-Q, pectin, starch, lignin, and lipids. Additional examples are described as natural tar diluents in PCT WO 2007/012980 to Lipowicz, which is incorporated by reference herein in its entirety. The type or function of a smokeless tobacco ingredient prepared from a tobacco isolate will vary depending on the composition of the isolate, which can vary in part based on the extraction process employed, the portion of the tobacco plant involved, the type of chemical transformation utilized, and the like. Certain tobacco isolates can provide sugars, fillers, binders, disintegration or compressibility aids, or flavorants for the smokeless tobacco composition of the disclosure.

Representative smokeless tobacco compositions may incorporate tobacco in an amount of about 30-40 weight percent and tobacco-derived pectin as described herein in an amount of about 4 weight percent, based on the total dry weight of the smokeless tobacco composition. For example, in one embodiment, the smokeless tobacco composition comprises about 36 weight percent milled tobacco, about 4 weight percent tobacco-derived pectin, about 14 weight percent rice starch, about 6 weight percent rice flour, about 7 weight percent maltitol powder, and about 3 weight percent flavoring compounds, based on the total dry weight of the smokeless tobacco composition, wherein the remainder comprises one or more colorants, sweeteners, fillers, binders, pH adjusters, and salts. For example, the remainder can, in one embodiment, comprise titanium dioxide, xylitol, sorbitol, calcium carbonate, maltodextrin, xanthan gum, sodium hydroxide, and sodium chloride. The particular percentages and choice of ingredients will vary depending upon the desired flavor, texture, and other characteristics.

The manner by which the various components of the smokeless tobacco composition are combined may vary. The various components of the smokeless tobacco composition may be contacted, combined, or mixed together in conical-type blenders, mixing drums, ribbon blenders, or the like, such as a Hobart mixer. As such, the overall mixture of various components with the powdered tobacco components may be relatively uniform in nature. See also, for example, the types of methodologies set forth in U.S. Pat. No. 4,148,325 to Solomon et al.; U.S. Pat. No. 6,510,855 to Korte et al.; and U.S. Pat. No. 6,834,654 to Williams, each of which is incorporated herein by reference.

The smokeless tobacco product can be provided in any suitable predetermined shape or form. For example, in some embodiments, the smokeless tobacco product is provided in the form having a general shape of a pill, pellet, tablet, coin, bead, ovoid, obloid, cube, film, flake, stick, foam, gel, or the like. In some embodiments, the shape is determined by the shape of the mold in which the product is formed. Individual compositions can be sized such that they fit entirely in the user's mouth, or such that they fit only partially in the mouth. Thus, the preferred dimensions can vary.

Shapes such as, for example, rods and cubes can be formed by first extruding the material through a die having the desired cross-section (e.g., round or square) and then optionally cutting the extruded material into desired lengths. Techniques and equipment for extruding tobacco materials are set forth in U.S. Pat. No. 3,098,492 to Wursburg; U.S. Pat. No. 4,874,000 to Tamol et al.; U.S. Pat. No. 4,880,018 to Graves et al.; U.S. Pat. No. 4,989,620 to Keritsis et al.; U.S. Pat. No. 5,072,744 to Luke et al.; U.S. Pat. No. 5,829,453 to White et al.; and U.S. Pat. No. 6,182,670 to White et al.; each of which is incorporated herein by reference. Exemplary extrusion equipment suitable for use include food or gum extruders, or industrial pasta extruders such as Model TP 200/300 available from Emiliomiti, LLC of Italy. In some instances, a single machine may be capable of achieving multiple steps of the processes described herein, such as, for example, kneader systems available from Buss AG.

The smokeless tobacco product can be dried or moistened to reach the final desired moisture level. The moisture content of the smokeless tobacco product prior to use by a consumer can vary. Typically, the moisture content of the smokeless tobacco product, as present within a single unit of product prior to insertion into the mouth of the user, is within the range of about 5 to about 20 weight percent, often about 8 to about 15 weight percent, more often about 10 to about 13 weight percent, based on the total weight of the product unit, but may vary depending upon the specific form of the smokeless tobacco product.

The acidity or alkalinity of the smokeless tobacco product, which is often characterized in terms of pH, can vary. Typically, the pH of that formulation is at least about 6.5, and preferably at least about 7.5. Typically, the pH of that formulation will not exceed about 9.5, and often will not exceed about 9.0. A representative tobacco formulation exhibits a pH of about 6.8 to about 8.8 (e.g., about 7.4 to about 8.2). A representative technique for determining the pH of a smokeless tobacco formulation involves dispersing 5 g of that formulation in 100 ml of high performance liquid chromatography water, and measuring the pH of the resulting suspension/solution (e.g., with a pH meter).

The compositions of the present invention may be dissolvable. As used herein, the terms “dissolve,” “dissolving,” and “dissolvable” refer to compositions having aqueous-soluble components that interact with moisture in the oral cavity and enter into solution, thereby causing gradual consumption of the product. According to one aspect, the dissolvable smokeless tobacco product is capable of lasting in the user's mouth for a given period of time until it completely dissolves. Dissolution rates of the present smokeless tobacco products can vary over a wide range, from less than about 1 minute to about 60 minutes. For example, fast release compositions typically dissolve and/or release the active component in less than about 2 minutes, often less than about 1 minute (e.g., less than about 50 seconds, less than about 40 seconds, less than about 30 seconds, or less than about 20 seconds). Dissolution can occur by any means, such as melting, mechanical disruption (e.g., chewing), enzymatic or other chemical degradation, or by disruption of the interaction between the components of the product. In some embodiments, the products can be meltable as discussed, for example, in U.S. application Ser. No. 12/854,342 to Cantrell et al., filed Aug. 11, 2010. In other embodiments, the compositions do not dissolve during the smokeless tobacco product's residence in the user's mouth.

According to some embodiments, the smokeless tobacco composition may be coated with a coating substance. For example, a glazing or anti-sticking coating substance, such as, for example, CAPOL 410 (available from Centerchem, Inc.), may be applied to the smokeless tobacco composition to provide free-flowing properties. Outer coatings can also help to improve storage stability of the smokeless tobacco products of the present disclosure as well as improve the packaging process by reducing friability and dusting. Devices for providing outer coating layers to the products of the present disclosure include pan coaters and spray coaters, and particularly include the coating devices available as CompuLab 24, CompuLab 36, Accela-Cota 48 and Accela-Cota 60 from Thomas Engineering.

An exemplary outer coating comprises a film-forming polymer, such as a cellulosic polymer, an optional plasticizer, and optional flavorants, colorants, salts, sweeteners or other additives of the types set forth herein. The coating compositions are usually aqueous in nature and can be applied using any pellet or tablet coating technique known in the art, such as pan coating. Exemplary film-forming polymers include cellulosic polymers such as methylcellulose, hydroxypropyl cellulose (HPC), hydroxypropyl methylcellulose (HPMC), hydroxyethyl cellulose, and carboxy methylcellulose. Exemplary plasticizers include aqueous solutions or emulsions of glyceryl monostearate and triethyl citrate. Exemplary coating compositions and methods of application are described in U.S. application Ser. No. 12/876,785 to Hunt et al.; filed Sep. 7, 2010, and which is incorporated by reference herein.

Although the foregoing description focuses on compositions that are uniform throughout each product unit, products can also be formed with multiple different formulations having different properties in the same product unit. For example, two different compositions could be co-extruded to form a product with different characteristics across its cross-section. Such a process could be used to provide a product with two different compositions featuring different dissolution rates such that a first portion of the product dissolves at a first rate (e.g., a faster rate) and a second portion dissolves at a second, slower rate.

According to some aspects, the tobacco component of the smokeless tobacco composition can be replaced or supplemented with other suitable botanical components such as, for example, tea particulates, coffee particulates, herbal particulates, spice particulates and/or combinations thereof. The particulates may be typically provided in a powder form, which may be extracted from an appropriate botanical source.

Products of the present disclosure can be packaged and stored in any suitable packaging. See, for example, the various types of containers for smokeless types of products that are set forth in U.S. Pat. No. 7,014,039 to Henson et al.; U.S. Pat. No. 7,537,110 to Kutsch et al.; U.S. Pat. No. 7,584,843 to Kutsch et al.; D592,956 to Thiellier and D594,154 to Patel et al.; US Pat. Pub. Nos. 2008/0173317 to Robinson et al.; 2009/0014343 to Clark et al.; 2009/0014450 to Bjorkholm; 2009/0250360 to Bellamah et al.; 2009/0266837 to Gelardi et al.; 2009/0223989 to Gelardi; 2009/0230003 to Thiellier; 2010/0084424 to Gelardi; and 2010/0133140 to Bailey et al; and U.S. patent application Ser. No. 29/342,212, filed Aug. 20, 2009, to Bailey et al.; Ser. No. 12/425,180, filed Apr. 16, 2009, to Bailey et al.; Ser. No. 12/685,819, filed Jan. 12, 2010, to Bailey et al.; and Ser. No. 12/814,015, filed Jun. 11, 2010, to Gelardi et al., which are incorporated herein by reference.

Experimental

The following example is provided to illustrate further aspects associated with the present disclosure, but should not be construed as limiting the scope thereof. Unless otherwise noted, all parts and percentages are by dry weight.

Approximately 800 pounds of air-cured burley tobacco (lamina and stem) are processed to extract and dry the pectin component as follows. To about 14,400 pounds of well water is added about 80 pounds of oxalic acid and about 80 pounds of ammonium oxalate. The resulting mixture is agitated until the oxalic acid and ammonium oxalate are dissolved to form a solution. The tobacco is added to the solution and the resulting mixture is heated at about 95-98° C. for about 90 minutes. The tobacco is removed from the mixture by filtration (additionally or alternatively, centrifugation can be used). The resulting liquid is collected once it has reached a desired level of clarity. It may be necessary to repeat the filtration/centrifugation steps two or more times to achieve the desired level of clarity. The liquid is then concentrated under vacuum until the product comprises approximately 9-11% solids.

Ethanol is added to the concentrated material in an amount of 1.2 times the amount of the concentrate by weight to give a dilute concentrate. The dilute concentrate is cooled to between about 5 and 7° C. The dilute concentrate is centrifuged to isolate the solid material that has formed. The solid material is rinsed in 50% ethanol in water (v/v) and then in 100% ethanol and the rinsed solid is isolated by centrifugation. The combined solid material is dried in a tray dryer under full vacuum, with hot water circulation at 55° C. in a jacket of the dryer. After a minimum of 6 hours, the sample is removed and tested to ensure that it comprises less than 5% moisture by weight. If the sample does not meet this requirement, it is further dried to give the isolated pectin product. Based on the original 800 g of tobacco material, 30 g of pectin product was isolated, in the form of a dark brown powder.

The dark brown powder is used in a dissolvable smokeless tobacco formulation typically comprising a tobacco blend and pullulan binder. Instead of the pullulan binder, the dark brown powder isolated as described above is used. The smokeless tobacco formulation comprises about 36 weight percent milled tobacco, about 4 weight percent of the dark brown powder (pectin component), about 14 weight percent rice starch, about 6 weight percent rice flour, about 7 weight percent maltitol powder, and about 3 weight percent flavoring compounds, based on the total dry weight of the smokeless tobacco composition. The formulation also includes minor amounts of titanium dioxide, xylitol, sorbitol, calcium carbonate, maltodextrin, xanthan gum, sodium hydroxide, and sodium chloride.

The resulting smokeless tobacco product was evaluated by informal sensory evaluations. The evaluations noted no discernable differences related to mouth-feel, color, or other visual attributes for the experimental finished product as opposed to the control product. The trial product containing tobacco-derived pectin exhibits reduced stick tackiness and increased rigidity as compared to the control material during processing. Both of these characteristics are considered positive attributes for this type of formulation.

Many modifications and other embodiments of the invention will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing description. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. A smokeless tobacco product configured for insertion into the mouth of a user, the smokeless tobacco product comprising a tobacco material and a binder component, the binder component comprising a tobacco-derived pectin material in an amount of at least about 2% by weight, based on the total dry weight of the smokeless tobacco product.

2. The smokeless tobacco product of claim 1, wherein the tobacco-derived pectin material is the only binder component therein.

3. The smokeless tobacco product of claim 1, wherein the smokeless tobacco product is extruded.

4. The smokeless tobacco product of claim 1, wherein the smokeless tobacco product is in the form of a pill, pellet, tablet, coin, bead, ovoid, obloid, cube, film, flake, stick, foam, or gel.

5. The smokeless tobacco product of claim 1, wherein the smokeless tobacco product is dissolvable.

6. The smokeless tobacco product of claim 1, wherein the smokeless tobacco product comprises greater than about 3% by weight of the tobacco-derived pectin material.

7. The smokeless tobacco product of claim 7, wherein the smokeless tobacco product comprises greater than about 4% by weight of tobacco-derived pectin material.

8. The smokeless tobacco product of claim 1, further comprising one or more components selected from the group consisting of flavorants, sweeteners, salts, fillers, fats, emulsifiers, gelling agents, disintegration aids, compressability aids, colorants, humectants, pH adjusters, buffering agents, oral care additives, preservatives, syrups, and mixtures thereof.

9. The smokeless tobacco product of claim 1, wherein the tobacco material is in particulate form with an average particle size of less than about 50 microns.

10. The smokeless tobacco product of claim 1, comprising:

a tobacco material in an amount of about 20 to about 50 dry weight percent;

a tobacco-derived pectin material in an amount of about 2 to about 10 dry weight percent;

one or more fillers in an amount of about 10 to about 40 dry weight percent;

one or more sweeteners in any amount of about 5 to about 15 dry weight percent;

and at least one flavorant in an amount up to about 5 dry weight percent.

11. The smokeless tobacco product of claim 10, wherein the tobacco material is a milled tobacco material or an aqueous tobacco extract.

12. The smokeless tobacco product of claim 10, wherein the one or more fillers comprise at least one rice-derived filler material.

13. The smokeless tobacco product of claim 10, wherein the one or more sweeteners comprises at least one sugar alcohol.

14. The smokeless tobacco product of claim 10, further comprising a binder in the form of a natural gum.

15. A method of preparing a smokeless tobacco product, comprising:

extracting pectin from a tobacco material to form a tobacco-derived pectin material; and

combining the tobacco-derived pectin material with a second tobacco material to form a smokeless tobacco composition; and

incorporating the resulting composition into a smokeless tobacco product, wherein the tobacco-derived pectin material is present in an amount of at least about 2% by dry weight of the smokeless tobacco product.

16. The method of claim 15, wherein the pectin material is present in an amount of at least about 3% by dry weight of the smokeless tobacco product.

17. The method of claim 16, wherein the pectin material is present in an amount of at least about 4% by dry weight of the smokeless tobacco product.