CIGARETTE PACKING PROCESSES, SYSTEMS, AND PRODUCTS

Abstract

Provided herein are systems, apparatuses, and methods of manufacturing high quality cigarettes, as well as products produced thereby. Such systems, apparatuses, and methods are particularly suitable for manufacturing products using smokable materials that are generally considered difficult to process, such as those that have high resin content, low density (or are fluffy), and/or are sticky (e.g., cannabis flower).

Description

CROSS-REFERENCE

This application claims benefit of U.S. Provisional Application No. 62/645,289, filed on Mar. 20, 2018, which is incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

Being designed for packing tobacco only, traditional cigarette packing systems are limited in their capability to pack a wide range of smoking materials. For instance, typical tobacco packing systems are utilized to pack tobacco products which are typically pressed and cut or shredded, whereas other smokable materials (including, e.g., smokable tobacco) that is ground or chopped cannot be readily used in such systems. Other smoking materials also have varying densities, stickiness, resin content, packability, and other variations. Attempts to utilize typical tobacco packing systems for preparing cigarettes of other materials, particularly sticky, high-resin materials have met with limited success. Such limitations are, at least in part, due to the stickiness of such materials, which tends to clog and otherwise disrupt processing equipment. As a result, processing of non-tobacco smoking materials has been very limited, with high-throughput processes and equipment leading to inferior products (such as producing cigarettes that have loosely packed smoking material, burn unevenly (e.g., running or canoeing), lose product out the open end, lose the burning ember, uneven administration of smoke content, or the like). In particularly, processes such as those using vibrational packing techniques alone or combined with gravity or centrifugal force fail to provide sufficient packing to produce a homogenous pack, particularly at the end of the pack material distal to the loading end. This poor packing, generally seen initially at least at the distal end, leads to poor packing throughout the cigarette initially and/or over time, which in turn leads to poor burning and delivery results. As a result, high quality products (e.g., cannabis products) are limited to those that are produced on a much smaller scale (e.g., hand-rolled) and are not commercially viable on a mass production scale and/or price point.

SUMMARY OF THE INVENTION

Provided herein are processes, systems, and apparatuses suitable for producing high quality cigarette products. In some instances, such processes, systems, and apparatuses facilitate the formation of cigarette products that have highly uniform, high density packing. Moreover, in certain instances, processes, systems, and apparatuses provided herein facilitate the formation of products that provide an even burn with even a consistent flavor and/or delivery profile. Also provided in certain embodiments herein are products produced or able to be produced by such processes or with such systems and apparatuses. In specific embodiments, products (or cigarettes) provided herein are drug delivery devices for providing one or more cannabinoid (CBD) to an individual in need thereof.

In certain embodiments, provided herein are processes, systems and apparatuses for packing a cigarette. In some embodiments, a process provided herein comprises (or the system or apparatus is configured to) (i) providing a pre-formed wrapper roll (e.g., the pre-formed wrapper roll having a first end (e.g., and a first opening at the first end) and a second end (e.g., and comprising a second opening at the second end)); and (ii) providing a pressure differential to the pre-formed wrapper roll. In specific embodiments, the pressure differential is provided by providing a higher pressure at the first end (e.g., opening thereof) than at the second end (e.g., opening thereof) of the pre-formed wrapper roll. In some instances, the pressure differential is provided by providing pressurized gas to a first end (or opening thereof) of the pre-formed wrapper roll and/or providing vacuum (e.g., referred to herein as reduced atmospheric pressure, such as an atmospheric pressure lower than ambient pressure, or less than 1 atmosphere (atm), less than 0.9 atm, less than 0.8 atm, less than 0.7 atm, less than 0.5 atm, less than 0.3 atm, or the like (wherein 1 atm is equivalent to 101.325 kPa)) to the second end (or opening thereof) of the pre-formed wrapper roll.

In some embodiments, a process provided herein comprises (or the systems or apparatus is configured to) providing pressurized gas to an opening of a pre-formed wrapper roll. In more specific embodiments, the pressurized gas is provided to the first (e.g., larger) opening thereof, wherein the pre-formed wrapper roll further comprises a second (e.g., smaller) opening, the second opening having a crutch, such as a rolled paper or filter, configured in proximity thereof. In still more specific embodiments, the pre-formed wrapper roll comprises a wrapper material configured in a rolled (e.g., cylindrical or conical) shape and having an interior surface defining an interior space, the crutch being configured within the interior space and in proximity to the second (e.g., smaller, such as in a conical configuration) opening. In certain embodiments, the process comprises applying pressurized gas to the first opening of the pre-formed wrapper roll, such pressurized gas flowing into the pre-formed wrapper roll and out of the second opening of the pre-formed wrapper roll. In some embodiments, the wrapper roll comprises a crutch in proximity to the second opening, the crutch comprising sufficient void space (e.g., is sufficiently porous) therein to allow pressurized gas to flow therethrough.

In some embodiments, provided herein is a method for manufacturing a cigarette, the method comprising:

• • a. loading a plurality of pre-formed wrapper rolls with raw materials to form a plurality of loaded wrapper rolls;
  • b. seating a packing apparatus (e.g., seating body thereof) with a plurality of pre-formed wrapper rolls; and
  • c. packing the raw material in the plurality of loaded wrapper rolls by applying a pressure differential thereto (e.g., to the ends thereof, such as wherein pressurized gas is applied to a first end of the loaded wrapper rolls and/or a reduced pressure is applied to a second end of the loaded wrapper rolls).

In certain embodiments, provided herein is a method for manufacturing a cigarette, the method comprising:

• • a. loading a plurality of pre-formed wrapper rolls with raw materials (e.g., particles thereof) to form a plurality of loaded wrapper rolls;
  • b. seating a (e.g., gas) packing apparatus (e.g., seating body thereof) with a plurality of pre-formed wrapper rolls; and
  • c. packing the raw material (e.g., particles thereof) in the plurality of loaded wrapper rolls by applying pressurized gas (e.g., 1-100 psi, such as about 20 psi to about 50 psi) (and/or reduced pressure) thereto.

In specific embodiments, a plurality of pre-formed wrapper rolls are seated within the packing apparatus (e.g., seating body thereof) prior to loading the raw material into the plurality of pre-formed wrapper rolls. In more specific embodiments, following loading of the pre-formed wrapper rolls with raw material within the gas packing apparatus (e.g., seating body thereof), the raw material is packed (e.g., gas packed) within the wrapper rolls.

In certain embodiments, any process provided herein further comprises reducing the average size of a raw material (e.g., whole or parts of tobacco and/or cannabis leaf and/or flower) to produce raw material particles, such as by a method described herein and/or having the particle parameters described herein.

In some embodiments, any process provided herein comprises providing raw material particles, such as by a process described herein, and separating raw material particles having a defined particle size from larger raw material bodies to provide segregated raw material particles. In certain instances, the raw material loaded into a pre-formed paper roll provided herein are segregated raw material particles.

In certain embodiments, any process provided herein comprises stocking a raw material storage reservoir with the raw materials, such as raw material particles, particularly segregated raw material particles. In other words, in some instances, provided herein is a process comprising loading raw material (e.g., segregated raw material particles) into a storage reservoir.

In some embodiments, any process provided herein comprises stocking a wrapper storage apparatus with a plurality of pre-formed wrapper rolls (e.g., loading pre-formed wrapper rolls into a wrapper storage apparatus).

In certain embodiments, any process provided herein comprises applying vibration (e.g., via any suitable process, such as tapping or shaking) to the plurality of wrapper rolls, such as during loading. In some instances, such application of vibration to the plurality of wrapper rolls is utilized to facilitate loading of the raw material into the pre-formed wrapper roll (e.g., not to pack the raw material into the pre-formed wrapper roll).

In some embodiments, any process provided herein comprises seating a seating body of a packing apparatus with a plurality of pre-formed wrapper rolls. In specific embodiments, pre-formed wrapper rolls are positioned into the seating body of a packing apparatus, followed by loading of raw material into the plurality of pre-formed wrapper rolls, and subsequently followed by packing of the raw material within the pre-formed wrapper roll (e.g., via pressurized gas and/or reduced pressure application thereto). In more specific embodiments, the process comprises (i) transferring pre-formed wrapper rolls from a wrapper storage apparatus to the seating body of the packing apparatus (e.g., thereby providing seated, pre-formed wrapper rolls, (ii) loading the plurality of pre-formed wrapper rolls with raw material, and (iii) packing of the raw material within the preformed wrapper roll (e.g., via pressurized gas or reduced pressure application thereto). In alternative embodiments, a process provided herein comprises loading biomass into aa plurality of pre-formed wrapper rolls, such as by hand, and transferring the plurality of loaded wrapper rolls to the packing apparatus. In still other alternative embodiments, the pre-formed wrapper rolls are seated within a seating body of a loading apparatus (e.g., the pre-formed wrapper rolls being transferred to the loading apparatus from a wrapper storage apparatus), followed by loading of the pre-formed wrapper rolls (e.g., such pre-formed wrapper rolls being configured within the seating body of the loading apparatus during loading), transferring the loaded, pre-formed wrapper rolls from the seating body of the loading apparatus to the seating body of a packing apparatus, and subsequently packing the raw material within the loaded pre-formed wrapper rolls. In some preferred embodiments, a single seating body is utilized in conjunction with a loading apparatus and a packing apparatus. For example, in some embodiments herein, (i) a plurality of pre-formed wrapper rolls are seated within the seating body of a packing apparatus (e.g., the pre-formed wrapper rolls being transferred thereto from a wrapper storage apparatus), (ii) configuring the seating body of the packing apparatus within the loading apparatus, (iii) loading raw material into the pre-formed wrapper rolls, (iv) removing the seating body of the packing apparatus from the loading apparatus, (v) configuring the seating body of the packing apparatus within the packing apparatus, and (vi) packing the raw material within the loaded pre-formed wrapper rolls, such as through use of a pressure differential (e.g., by applying pressurized gas and/or reduced pressure to the pre-formed wrapper rolls) (e.g., wherein such steps are followed in the denoted order (with optional intervening steps contemplated)).

In certain embodiments, any process provided herein comprises physically packing the loaded and packed raw material within the loaded wrapper roll(s). In some embodiments, physical packing is achieved using any suitable object or device, such as a dowel (e.g., metal dowel). In some instances, such as wherein the cigarette is hand-finished (e.g., with a twist of the pre-formed wrapper roll extending beyond the loaded and packed raw material within the pre-formed wrapper roll), the gas/vacuum packed raw material is physically packed by hand. In other instances, a system or method provided herein utilizes a finishing apparatus that physically packs the (e.g., loaded and gas/vacuum packed) raw material within the pre-formed wrapper roll and/or twists a portion of the pre-formed wrapper roll that extends beyond the loaded and packed raw material within the pre-formed wrapper roll. In some instances, a process and/or system provided herein utilizes a physical packing step, object, or apparatus so as to provide gentle physical packing of the top surface of (e.g., loaded and packed) raw material to provide an even top surface of material within the pre-formed wrapper roll, such as to provide a cigarette with an aesthetically pleasing appearance and/or good initial burn.

In some specific embodiments, a method provided herein comprises:

• • a. reducing the average size of a raw material (e.g., whole or parts of tobacco and/or cannabis leaf and/or flower) to produce raw material particles;
  • b. separating raw material particles having a defined particle size from larger raw material bodies to provide segregated raw material particles;
  • c. loading the plurality of (e.g., seated) pre-formed wrapper rolls with the segregated raw materials particles;
  • d. seating a seating body of a (e.g., pressure differential, such as gas and/or vacuum) packing apparatus with a plurality of pre-formed wrapper rolls (e.g., (i) transferring pre-formed wrapper rolls from the wrapper storage apparatus to the seating body of the packing apparatus (e.g., thereby providing seated, pre-formed wrapper rolls) and loading the plurality of pre-formed wrapper rolls with the raw material, or (ii) transferring the plurality of loaded wrapper rolls to the packing apparatus if loaded by hand or (iii) using a loading apparatus, such as whereby pre-formed wrapper rolls are transferred from the wrapper storage apparatus to a seating body of a loading apparatus, after which the pre-formed wrapper rolls are loading with the segregated raw material particles and subsequently transferring such loaded, pre-formed wrapper rolls to the seating body of the packing apparatus); and
  • e. packing the segregated raw materials particles in the plurality of loaded wrapper rolls by applying pressurized gas (e.g., 1-100 psi, such as about 20 psi to about 50 psi) (and/or reduced pressure) thereto.

In specific embodiments, a method provided herein comprises:

• • a. reducing the average size of a raw material (e.g., whole or parts of tobacco and/or cannabis leaf and/or flower) to produce raw material particles;
  • b. separating raw material particles having a defined particle size from larger raw material bodies to provide segregated raw material particles;
  • c. (e.g., optionally) stocking a raw material storage reservoir with the segregated raw materials particles (e.g., loading segregated raw materials into the storage reservoir);
  • d. (e.g., optionally) stocking a wrapper storage apparatus with a plurality of pre-formed wrapper rolls (e.g., loading pre-formed wrapper rolls into a wrapper storage apparatus);
  • e. loading the plurality of (e.g., seated) pre-formed wrapper rolls with the segregated raw materials particles;
  • f. (e.g., optionally) applying vibration (e.g., via tapping or shaking) to the plurality of loaded wrapper rolls;
  • g. seating a seating body of a (e.g., pressure differential, such as gas and/or vacuum) packing apparatus with a plurality of pre-formed wrapper rolls (e.g., (i) transferring such pre-formed wrapper rolls from the wrapper storage apparatus to the seating body of the packing apparatus (e.g., thereby providing seated, pre-formed wrapper rolls) and loading the plurality of pre-formed wrapper rolls with the segregated raw materials particles, or (ii) transferring the plurality of loaded wrapper rolls to the packing apparatus if loaded by hand or (iii) using a loading apparatus, such as whereby pre-formed wrapper rolls are transferred from the wrapper storage apparatus to a seating body of a loading apparatus, after which the pre-formed wrapper rolls are loading with the segregated raw material particles and subsequently transferring such loaded, pre-formed wrapper rolls to the seating body of the packing apparatus);
  • h. packing the segregated raw materials particles in the plurality of loaded wrapper rolls by applying pressurized gas (e.g., 1-100 psi, such as about 20 psi to about 50 psi) (and/or reduced pressure) thereto; and
  • i. (e.g., optionally) physically packing the segregated raw materials particles in the plurality of loaded wrapper rolls (e.g., a gentle physical packing of the top surface of the loaded and packed material to provide an even top surface of material within the pre-formed wrapper roll).

In certain embodiments, the pre-formed wrapper rolls are loaded in the (e.g., pressure differential or gas) packing apparatus (e.g., while seated within the seating body thereof). In other embodiments, the pre-formed wrapper rolls are loaded prior to seating of the (loaded) pre-formed wrapper rolls into the (e.g., gas) packing apparatus. In general, the (e.g., pressure differential or gas) packing apparatus is configured to seat and/or secure the pre-formed wrapper rolls during (e.g., pressure differential or gas) packing. In general, wrapper paper of the wrapper rolls is extremely delicate and easily torn. As such, in some instances, gently securing the wrapper rolls, such as described herein is important to minimizing packing failures, while also achieving good and uniform packing (e.g., without air gaps). In many instances, competitive products using fluffy, sticky, and/or high-resin raw materials (such as cannabis) produced have fail rates of up to 20% or more (i.e., wrapper rolls fail up to 20% or more during competitive packing processes), leading to high manufacturing costs. By contrast, processes, systems, and/or apparatuses herein have been demonstrated to have fail low fail rates. In some instances, processes, systems, and/or apparatuses provide herein have a (packing) fail rate of about 10% or less, about 5% or less, or about 3% or less, which represents a significant improvement over some (particularly high throughput) manufacturing systems.

In specific embodiments, a process herein comprises (or a system or apparatus herein is configured to facilitate) transferring pre-formed wrapper rolls from a wrapper storage apparatus to a loading apparatus (e.g., wherein the pre-formed wrapper rolls are at least partially filled with raw material) prior to seating pre-formed wrapper roll(s) in a (e.g., pressure differential or gas) packing apparatus (e.g., seating body thereof) provided herein. In alternative embodiments, the pre-formed wrapper rolls are loaded with raw material by hand prior to securing in the (e.g., pressure differential or gas) packing apparatus (e.g., seating body thereof). In still other embodiments, the pre-formed wrapper rolls are secured within the (e.g., pressure differential or gas) packing apparatus (e.g., seating body thereof) (e.g., the pre-formed wrapper rolls being transferred therefrom from a wrapper storage apparatus) and loaded with raw material while secured within the (e.g., pressure differential or gas) packing apparatus.

Raw Materials

Any suitable materials (e.g., raw materials), such as any suitable biomass (e.g., smokable biomass), are optionally utilized in the processes, systems, apparatuses, and products provided herein. In certain embodiments, raw materials (or biomass) include tobacco, cannabis, herbs, or the like. In specific embodiments, the raw materials or biomass is cannabis, such as low THC (trans-Δ⁹-tetrahydrocannabinol) content cannabis (also referred to herein as “hemp”). In specific instances, hemp provided herein is cannabis biomass having a THC content of 0.3 wt. % or less, such as on a dried weight basis. In some embodiments, raw materials are pre-processed prior to use, such as described herein.

In certain embodiments, such raw materials comprise whole or parts of tobacco and/or cannabis materials (e.g., leaf and/or flower), and/or other herbs, such as dried herbs. In some embodiments, a method provided herein comprises reducing the average size of a raw material to produce raw material particles, such as having a defined or desired size. In specific embodiments, reducing the average size of the raw material is achieved using any suitable process, such as by way of non-limiting example, by chopping, grinding, tearing, and/or whipping the raw material into smaller bodies. In preferred embodiments, the raw material is reduced in size using whipping and/or tearing mechanisms, such as to separate the raw materials, rather than chop or cut the raw materials. In certain instances, such as when cannabis flower is utilized as a raw material, whipping or tearing of the raw materials facilitates reduction of product size while leaving larger stems (i.e., not chopped). In some instances, such processes facilitate the removal of stems, which can contribute to high failure rates in producing quality product (e.g., without tearing wrapper materials), such as discussed herein (e.g., helps to greatly reduce failure rates, such as to about 10% or below, about 5% or below, about 3% or below, or the like).

In certain materials, the raw materials loaded into a pre-formed wrapper roll or product herein are in particle form. In specific embodiments, such particles have a defined size, such as having been segregated or isolated based on size from larger materials (e.g., incompletely reduced raw materials, stems, etc.). In specific embodiments, raw material particles have an average size (e.g., longest dimension) of about 5 mm or less. In more specific embodiments, the particles have an average size (e.g., longest dimension) of about 3 mm or less. In more specific embodiments, the particles have an average size (e.g., longest dimension) of about 2 mm or less.

In certain embodiments, raw materials are loaded directly into pre-formed wrapper rolls. In other embodiments, raw materials are loaded into a storage reservoir prior to loading into the pre-formed wrapper rolls.

In certain embodiments, raw materials provided herein have a controlled moisture content (e.g., which may be dried or humidified prior to use). In some instances, the moisture content is about 2% to about 10%, such as about 4% to about 7% of the raw materials.

Sifting

In some embodiments, a process provided herein comprises (or a system or apparatus provided herein is configured to) separate, isolate, or otherwise segregate raw material particles having a defined particle size from larger raw material bodies to provide segregated raw material particles having a defined particle size, such as discussed herein. Any suitable method of segregating particles of desired size are optionally utilized. In specific embodiments, separating the raw material particles having a defined particle size from larger raw material bodies comprises sifting the particles through a sieve mesh. In more specific embodiments, separating the raw material particles having a defined particle size from larger raw material bodies comprises placing the particles on a sieve mesh and shaking or vibrating the sieve mesh. In some embodiments, segregated particles are loaded directly into a pre-formed wrapper roll, or are provided into a reservoir system, such as to facilitate automation.

Wrapper

In certain embodiments, a pre-formed wrapper roll provided herein comprises a wrapper material that is configured into a three-dimensional shape, such as a conical shape or a cylindrical shape. In some embodiments, the pre-formed wrapper rolls have a first end (e.g., with a first opening located at the first end) and a second end (e.g., with a second opening located at the second end), the first end being open to the interior of a three-dimensional structure defined by a wrapper material. In preferred embodiments, the three-dimensional shape is a conical shape, such as wherein the conical shape has a first opening (e.g., suitable for receiving raw materials therethrough) and a second opening (e.g., at the aperture of the conical structure). In specific embodiments, the pre-formed wrapper roll comprises a crutch a wrapper material, such as wherein the crutch is any suitable material, such as a rolled and/or folded paper, a filter, or any other suitable material, such as that facilitates maintenance of the pre-formed wrapper roll configuration. In specific embodiments, the crutch facilitates holding of the wrapper material in the configuration of the pre-formed wrapper roll. In certain embodiments, the crutch is configured in proximity to one opening or end of the three-dimensional structure, such as in proximity to the second opening or apex opening of a conical three-dimensional structure.

In specific embodiments, the pre-formed wrapper rolls have a first end and a second end, the first end having a first opening to the interior of a three-dimensional structure defined by a wrapper material, and the second end (e.g., the apex in a conical shape) having a second opening to the interior of the three-dimensional structure. In more specific embodiments, the second opening is smaller than the first opening, such as wherein the three-dimensional structure is a conical shape. In some embodiments, a crutch is configured within the interior structure of the pre-formed wrapper roll, such as in proximity to the second end or opening of the pre-formed wrapper roll.

In certain embodiments, the crutch is a filter, such as a porous filter. In specific embodiments, the porous filter is sufficiently porous to allow the free flow of gas (e.g., air) therethrough, such as when packing a cigarette as described herein. In more specific embodiments, the porous filter is sufficiently porous to allow the free flow of gas therethrough, without creating a backpressure (e.g., without creating a backpressure of greater than 20 psi, greater than 10 psi, greater than 5 psi, greater than 3 psi, or the like) within the pre-formed wrapper roll during (e.g., pressure differential, such as gas and/or vacuum) packing, such as described herein.

In various embodiments, any suitable wrapper material is utilized. In some preferred embodiments, the wrapper material is non-toxic during combustion. In some embodiments, the wrapper material comprises paper (e.g., rice paper, hemp paper, a cellulose-based (e.g., cellulose acetate) paper, or any suitable paper material), and/or tobacco and/or cannabis leaf.

In certain embodiments, a method or system provided herein comprises providing pre-formed wrapper rolls to the method or system. In specific embodiments, the method or system further comprises forming or comprises an apparatus for forming such pre-formed wrapper rolls.

Wrapper Storage

In various embodiments, the pre-formed wrapper roll is provided to the packing system (e.g., a seating body thereof) by any suitable process. In certain embodiments, the process comprises directly seating the pre-formed wrapper rolls into an apparatus (e.g., a seating body thereof) by hand. In other embodiments, the process comprises stocking a wrapper storage apparatus with a plurality of pre-formed wrapper rolls (e.g., followed by transferring the pre-formed wrapper rolls therefrom to a (e.g., loading or packing) seating body of an apparatus described herein). In some instances, such stocking facilitates a more streamlined and/or automated manufacturing process. In certain embodiments, pre-formed wrapper rolls are dispensed from the wrapper storage apparatus into an apparatus of a system provided herein, such as a (e.g., pressure differential or gas) packing apparatus (e.g., a seating body thereof), a loading apparatus (e.g., a seating body thereof), or other apparatus, as suitable. In specific embodiments, pre-formed wrapper rolls are transferred or dispensed from a wrapper storage apparatus into a loading apparatus (e.g., a seating body thereof), wherein the pre-formed wrapper rolls are loaded or at least partially filled with raw material, after which, such loaded, pre-formed wrapper rolls are transferred to dispensed into a (e.g., pressure differential or gas) packing apparatus, wherein the raw materials packed within the (e.g., pressure differential or gas) packing apparatus. In other embodiments, the seating body of the loading apparatus and the packing apparatus is the same seating body, and the step of transferring the loaded, pre-formed wrapper rolls from one seating body to another is omitted, thereby streamlining the manufacturing process.

In various embodiments, any suitable wrapper storage apparatus is utilized in a method or system provided herein. In certain embodiments, the wrapper storage comprises one or more hollow bodies, such as tube(s) (e.g., of any suitable shape, such as cylindrical, etc.), each hollow body (e.g., tube) having a length or height sufficient to receive and store a plurality of pre-formed wrapper rolls therewithin. In some embodiments, the hollow body (e.g., tube) of the wrapper storage comprises a receiving end configured to receive pre-formed wrapper rolls therethough and a dispensing end configured to dispense pre-formed wrapper rolls therethrough (e.g., delivering such pre-formed wrapper rolls into a loading apparatus). In specific embodiments, a process provided herein comprises applying a pressurized gas (e.g., such as having pressure described herein) to the receiving end of one or more hollow tube of the wrapper storage and/or applying reduced pressure (e.g., such as having pressure described herein) to the dispensing end of the one or more hollow tube of the wrapper storage (e.g., thereby facilitating dispensing a pre-formed wrapper roll into a loading apparatus).

Loading & Vibration Packing

In certain embodiments, the pre-formed wrapper rolls are loaded with raw materials. In certain embodiments, the pre-formed wrapper rolls are pre-loaded with raw materials. In other embodiments, a process provided herein comprises loading the pre-formed wrapper rolls with raw material. Any suitable amount of raw material is optionally loaded into the pre-formed wrapper rolls. The amount of raw material that can be loaded into the pre-formed wrapper rolls will depend on a variety of factors, such as density of the raw material, packability of the raw material, volume available in the interior of the pre-formed wrapper roll (e.g., based on the size of the wrapper and three-dimensional configuration). In certain embodiments, about 0.2 g to about 5 g (e.g., about 0.25 g, about 0.5 g, about 0.75 g, or the like) of raw materials is loaded into the pre-formed wrapper rolls. In certain embodiments, the raw material is loaded into the pre-formed wrapper roll until it is flush with the receiving opening (e.g., the first (or larger—in conical configurations) opening of the pre-formed wrapper roll). In other embodiments, the raw material is not completely filled (e.g., initially and/or following differential pressure/gas packing) to the receiving end or opening of the pre-formed wrapper rolls. In certain embodiments, leaving room at the end of the pre-formed wrapper roll allows for folding, twisting, or other sealing process for securing the raw materials within the cigarette.

In certain embodiments, pre-formed wrapper rolls are loaded with a pre-determined volume of raw materials. In specific embodiments, the pre-determined volume of raw materials is determined by measuring the volume of a known mass of raw materials (e.g., different raw materials have different densities). Specifically, in certain embodiments, a loading step of any process provided herein comprises determining the volume of raw material that provides a desired mass of raw material, measuring out raw material in the determined volume, and loading the measured volume of raw material into the pre-formed wrapper rolls. In more general instances, a loading step of any process provided herein comprises measuring out raw material in a pre-determined volume, and loading the measured volume of raw material into (e.g., each) pre-formed wrapper roll.

In some embodiments, pre-formed wrapper rolls are loaded into a loading apparatus and filled with raw materials. In some embodiments, (e.g., prior to loading with raw materials) the one or more of the plurality of pre-formed wrapper rolls is loaded into a loading apparatus, the loading apparatus comprising a loading body, the loading body having one or more loading bore therethrough, the one or more of the plurality of pre-formed wrapper rolls being loaded into the plurality one or more loading bore. In certain embodiments, a loading apparatus provided herein comprises a receiving surface. In specific embodiments, a process provided herein comprises charging a receiving surface with raw material (e.g., from a raw material storage reservoir). In more specific embodiments, the pre-formed wrapper rolls are loaded or at least partially filled by transferring raw materials from the receiving surface into the pre-formed wrapper rolls.

In certain embodiments, pre-formed wrapper rolls loaded or charged with raw materials are subjected to vibration (e.g., by tapping, using speakers, shaking, or the like) (e.g., such as when seated in a loading apparatus (e.g., loading body thereof), (e.g., pressure differential or gas) packing apparatus (e.g., seating body thereof), or in any other suitable disposition). In certain embodiments, application of such vibration facilitates preliminary packing (or pre-packing) of the raw materials in the pre-formed wrapper rolls. In some instances, such vibration pre-packing is necessary or helpful to charge the pre-formed wrapper rolls with a desired amount of raw materials. In some instances, other cigarettes are formed by using vibrational or comparable packing techniques in producing cigarettes comprising sticky, fluffy, and/or high-resin raw materials (e.g., cannabis), but such packing is insufficient to produce a high-quality cigarette (particularly one comprising a fluffy, sticky, and/or high-resin raw material), such as without the differential pressure (e.g., gas) packing described herein. As discussed herein, such cigarettes are poorly and inconsistently packed and have a poor and inconsistent burn.

In certain embodiments, wherein a loading body of a loading apparatus is utilized, a process herein further comprises transferring loaded pre-formed wrapper rolls to a (e.g., pressure differential or gas) packing apparatus (e.g., seating body thereof). In specific instances, a loading body of a loading apparatus herein comprises a plurality of bores, in which the pre-formed wrapper rolls are configured during loading. In some instances, one end (i.e., the non-receiving end or the second end) of the wrapper roll rests a removable base of the loading apparatus, upon which the one or more pre-formed wrapper roll rests when loaded within the loading bore. In certain embodiments, transfer of pre-formed wrapper rolls from the loading body (e.g., of a loading apparatus) to the (e.g., pressure differential or gas) packing apparatus (e.g, seating body thereof) is achieved by (i) aligning the bores of the loading apparatus with the bores of the seating body of a (e.g., pressure differential or gas) packing apparatus, with the removable base of the loading body configured therebetween, and (ii) the removable base, allowing the pre-formed wrapper rolls to drop or otherwise transfer into and become seated within the bores of a seating body of a (e.g., pressure differential or gas) packing apparatus, such as described herein.

In some instances, a single apparatus performs the function of both the loading body of a loading apparatus (e.g., also referred to herein as a seating body of a loading apparatus) and the seating body of a (e.g., pressure differential or gas) packing apparatus (e.g., which are collectively referred to herein as a seating body of a packing apparatus because of the ability of such a seating body to perform in that capacity).

Differential Pressure (e.g., Gas) Packing

In certain embodiments, a process provided herein comprises seating pre-formed wrapper rolls in a (e.g., pressure differential or gas) packing apparatus (e.g., a seating body thereof). In various embodiments, the pre-formed wrapper rolls seated within the (e.g., pressure differential or gas) packing apparatus (e.g., seating body thereof) are either charged or loaded with raw materials prior to seating in the (e.g., pressure differential or gas) packing apparatus or may be charged or loaded with raw materials after loading in the (e.g., pressure differential or gas) packing apparatus (e.g., seating body thereof).

In certain embodiments, a packing apparatus comprises a seating body, the seating body comprising a plurality of bores therethrough. In specific embodiments, pre-formed wrapper rolls are seated within the plurality of bores within the seating body (e.g., wherein no more than one pre-formed wrapper roll is configured within each bore). In some embodiments, the bores of the seating body each comprise a first bore opening and a second bore opening, the pre-formed wrapper rolls being loaded into the bore through the first bore opening and seated within the bore. In specific embodiments, the bores of the seating body each comprise a first bore opening and a second bore opening, the pre-formed wrapper rolls having a first end and a second end, the first end (e.g., the end with the smaller opening in wrapper rolls having a conical configuration) being passed through the first and then second bore openings before being seated within the bore.

In some embodiments, the pre-formed wrapper rolls (e.g., each) comprise a first end and a second end, the first end having a first wrapper opening to the interior of a three-dimensional structure defined by a wrapper material, and the second end (e.g., the apex in a conical shape) having a second wrapper opening to the interior of the three-dimensional structure. In specific embodiments, the second wrapper opening is smaller than the first wrapper opening. In some embodiments, a (e.g., rolled or folded paper or porous filter) crutch is configured within the interior structure of the pre-formed wrapper roll in proximity to the second end. In specific embodiments, (e.g., when seated within a bore of a seating body provided herein) the entirety of the crutch is configured outside of the bore. In other words, in some instances, the crutch is passed completely through the seating bore or the crutch extends beyond the second bore opening in its entirety. As discussed herein, a significant difficulty in packing fluffy, stick, and/or high-resin raw materials (e.g., cannabis, such as hemp) is associated with a difficulty to achieve good uniformity in the pack at the end of the wrapper roll distal to the receiving end of the wrapper roll. In some instances, by configuring the crutch completely outside of the seating bore when packing, a tight packing is facilitated at or near the crutch (e.g., wrapped and/or rolled paper and/or filter). In certain instances, such configurations provide good overall packing within the cigarette. Other processes (particularly on a commercial scale) generally provide loose packing distal to the receiving end of the wrapper roll, leading to a loose overall pack as the raw materials settle. As such, in certain instances, good distal packing facilitates good overall packing over time of the cigarette, leading to good performance and burn of the cigarette when ultimately utilized (e.g., by a person in need thereof). In specific embodiments, the entirety of the crutch extends beyond the seating bore, as well as an additional portion of the wrapper roll. In specific embodiments, the crutch extends beyond the seating bore by at least 0.5 mm (e.g., at least 1 mm, at least 2 mm, at least 3 mm, or the like). In other words, in some instances, when seated, the entirety of the crutch, plus an additional amount protrudes from the second seating bore opening.

In some embodiments, the pre-formed wrapper roll has a conical configuration and the bore has a conical configuration (e.g., a conical frustum). In specific embodiments, the pre-formed wrapper roll has a conical configuration with an apex angle (wrapper apex angle) that is within 10 degrees (e.g., within 5 degrees, within 3 degrees, or the like) of an apex angle of the bore conical configuration (bore apex angle). In specific instances, such a matching configuration facilitates packing of raw material within the wrapper roll by ensuring gas flow through the pre-formed wrapper roll, rather than around it. In some instances, a system provided herein comprises a plurality of seating bodies, each seating body having a different bore configuration that corresponds to a specific pre-formed wrapper roll configuration (e.g., wherein a single seating body configuration is intended to be utilized in the system at any given time).

In certain embodiments, the bore of the seating body has any suitable configuration. In specific embodiments, the bore of the seating body is configured such that the pre-formed wrapper roll closely fits therein. In some embodiments, pre-formed wrapper rolls each have an exterior surface and the loading apparatus bores have an interior surface. In specific embodiments, when seated within a bore of a seating body, the exterior surface of the pre-formed wrapper roll is no more than 2 mm (e.g., no more than 1 mm, no more than 0.5 mm, no more than 0.3 mm, no more than 0.2 mm, or the like) from the interior surface of the apparatus bore (at its closest) at the first wrapper opening (i.e., the opening through which raw material is loaded). In more preferred embodiments, when seated within a bore of a seating body, the exterior surface of the pre-formed wrapper roll is no more than 2 mm (e.g., no more than 1 mm, no more than 0.5 mm, no more than 0.3 mm, no more than 0.2 mm, or the like) from the interior surface of the apparatus bore (at its closest) at any point within the bore wherein the pre-formed wrapper roll is seated. In certain instances, a close seating of the wrapper roll within the seating bore forces the pressurized gas to flow into and through the wrapper roll, facilitating good packing of the raw materials. In some instances, wherein poor seating within the seating bore allows gas to flow around the wrapper roll, rather than through it, diminishing or negating the gas/vacuum packing effect.

In some embodiments, a process herein comprises pressure differential packing raw materials (e.g., as particles or segregated particles) in a wrapper roll loaded with such raw materials by providing pressurized gas or reduced pressure into or to an opening of the wrapper roll. In specific embodiments, a gas is provided to the first opening of the wrapper roll (first wrapper opening) (i.e., the opening at the receiving end of or the opening through which the raw materials is loaded into the wrapper roll). In some specific embodiments, a reduced pressure is provided to the second opening of the wrapper roll (second wrapper opening) (i.e., the opening opposite the receiving end of or the opening through which the raw materials is loaded into the wrapper roll).

In certain embodiments, a process herein comprises gas packing raw materials (e.g., as particles or segregated particles) in a wrapper roll loaded with such raw materials by providing pressurized gas into an opening of the wrapper roll. In specific embodiments, the opening is the first opening of the wrapper roll (first wrapper opening) (i.e., the opening at the receiving end of or the opening through which the raw materials is loaded into the wrapper roll). In specific embodiments, the gas packing of the raw materials is performed while the wrapper roll is seated within a gas packing apparatus (e.g., within the seating bore of a seating body thereof), such as described herein.

In some embodiments, gas packing raw materials (e.g., particles or segregated particles thereof) in the plurality of loaded wrapper rolls is achieved by providing pressurized gas (e.g., 1-100 psi, such as about 20 psi to about 50 psi) into a (e.g., first) opening of a wrapper roll (e.g., loaded with raw materials) and/or (e.g., first) bore opening of the seating body (e.g., of a packing apparatus), such as wherein the loaded wrapper roll is seated therein (e.g., a seating bore thereof). In some embodiments, providing a pressure differential to the openings of a loaded wrapper roll provides a flow of gas into the first opening of the loaded wrapper roll and out of the second opening of the loaded wrapper roll. In specific embodiments, providing gas into a first opening of a loaded wrapper roll provides a flow of gas into the loaded wrapper roll and out of the second opening of the loaded wrapper roll. Similarly, in certain embodiments providing gas into a first opening of a seating bore opening provides a gas flow into the seating bore and out a second opening of the seating bore. In certain instances, such gas flow facilitates good packing without adverse effects when the pressure is removed due to back pressure effects. In some instances, such gas flow facilitates removal of small particles that would otherwise be consumed or inhaled by a user.

In certain embodiments, a plurality of loaded wrapper rolls are seated within a gas packing apparatus (e.g., seating body thereof), such as described herein, and pressurized gas is (e.g., concurrently) applied to the first opening of any two or more first openings of any two or more of the plurality of wrapper rolls. In some embodiments, concurrent application of gas pressure to two or more first openings is achieved via a gas manifold (e.g., a manifold system comprising one or more manifold body and one or more tube or hose, such as is necessary to connect the one or more manifold bodies to each other and/or a source of pressurized gas). In certain embodiments, pressurized gas is provided to at least one inlet of a gas manifold, and at least one outlet of the gas manifold is brought into proximity of at least one first opening of the plurality of wrapper rolls or to at least one bore opening of the gas packing apparatus, or the seating body thereof (e.g., a first bore opening thereof, the first bore opening being the opening through which the wrapper roll is loaded into the seating bore). In specific embodiments, pressurized gas is provided to at least one inlet of a gas manifold, and at least one outlet of the gas manifold is brought into proximity of multiple first openings of the plurality of wrapper rolls or to multiple bore openings of the gas packing apparatus, or the seating body thereof (e.g., thereby concurrently provided pressurized gas to a plurality of first openings of the plurality of wrapper rolls or bore openings of the gas packing apparatus, or seating body thereof. In some embodiments, when the manifold is brought into proximity of the first opening(s) of the plurality of wrapper rolls or to bore opening(s), the manifold outlet(s) are brought into contact with the bore opening(s), such as forming a seal or at least partial seal therewith. In various embodiments, the manifold comprises any number of suitable bodies, tubes, or hoses to collectively perform the function thereof. For example, in some instances, a manifold provided herein comprises a first body comprising the at least one inlet and a second body comprising the at least one outlet, the first and second bodies being connected in any suitable manner, such as via tubing and/or hosing. Similar configurations are also contemplated in providing reduced pressure to a plurality of pre-formed wrapper rolls or packing apparatus (e.g., seating body thereof) (e.g., except configured at the opposite opening of the pre-formed wrapper rolls or packing apparatus (e.g., seating bores of the seating body thereof) relative to the gas packing configurations).

In various embodiments, any suitable amount of pressure is utilized, such as about 1 to about 100 pounds per square inch (psi). In specific embodiments, the gas pressure utilized is about 30 to about 60 psi. In various embodiments, gas pressure is measured or determined at any point along the line, such as prior to the inlet of the manifold, or upon expulsion from the manifold (e.g., at one or more manifold outlet).

In some embodiments, similar effects (e.g., pressure differentials between the first and second openings of the wrapper roll) are achieved by applying reduced pressure to the second or opposing opening of the wrapper roll. In certain embodiments, both pressurized gas is provided to the first opening and reduced pressure is provided to the second opening of the wrapper roll. In some instances, with the combination of pressurized gas and reduced pressure provided at opposing ends of the wrapper roll, lower levels of pressurized gas is optionally utilized (e.g., wherein similar pressure differentials between the first and second openings are achieved).

Physical Packing

In some embodiments, a process herein comprises physically packing raw materials within loaded wrapper roll(s). In some instances, such physical packing is performed following gas/vacuum packing, such as to ensure a well packed raw material surface within the wrapper roll. In certain instances, a small amount of back pressure may be realized when gas/vacuum packing, which may result in a small amount of disruption at the surface of the packed raw material. In further or alternative instances, following gas/vacuum packing, an uneven packed surface is achieved. In some instances, physical packing provides a well packed and uniform surface. Physical packing is optionally achieved utilizing any suitable process, system or apparatus. In specific instances, physical packing is achieved utilizing a dowel, a piston, or the like. Physical packing is optionally manual or automated. In some instances, physical packing is achieved while seated within the bores of the seating apparatus, or in any other suitable apparatus or system.

Twisting

In some embodiments, following packing (e.g., following gas and/or vacuum packing or physical packing, if utilized) of the raw materials within the wrapper roll(s), a finished first end of the wrapper roll is produced. In some instances, the finished (e.g., first) end is a cut end, wherein packed raw material is exposed. In other instances, the finished (e.g., first) end is enclosed with folded, twisted, or otherwise configured wrapper material. In certain instances, the packed raw materials within the wrapper roll do not completely fill the wrapper roll. As a result, in some instances, the wrapper material extends beyond the packed raw materials. In certain embodiments, the wrapper material extending beyond the packed raw materials is trimmed (e.g., cut to provide an open end with exposed raw material), twisted, folded, or the like. In some instances, a process herein comprises twisting, folding, and/or removing a portion of or the first end of the wrapper material. In certain instances, such portion is all or part of a portion that extends (e.g., in the direction of the first end or opening) beyond the packed raw material particles within the wrapper roll.

Additive Coating

In certain embodiments, further treatment of the packed wrapper roll is done prior to finalization. For example, in some embodiments, additives are applied the exterior surface of the wrapper roll. In certain embodiments, the additives are liquids and/or solids. In some embodiments, an additive is applied to the external surface of the wrapper material, such as by spraying, dipping, painting, or otherwise coating a material on the wrapper material. In certain instances, the additive is applied as an oil, a liquid, a suspension, or a solution onto the wrapper material. In some instances, if a sticky substance (e.g., oil) is utilized, further application of solid materials (e.g., powders) are also optionally applied.

Systems

In certain embodiments, provided herein are systems and apparatuses for manufacturing cigarettes, such as according to a process described herein. In some embodiments, provided herein is a system for manufacturing a (e.g., tobacco or cannabis) cigarette, the system comprising a packing apparatus, the packing apparatus comprising a seating body configured to seat one or more pre-formed wrapper roll therewithin. In specific embodiments, the packing apparatus further comprises a manifold configured to provide a different pressure to a first end of the pre-formed wrapper roll than to the second end of the wrapper roll. In certain embodiments, the manifold is configured to provide pressurized gas into one or more pre-formed wrapper roll (e.g., a first end, as described herein, thereof) seated within the packing apparatus (e.g., seating body thereof). In some embodiments, the manifold is configured to provide reduced pressure into one or more pre-formed wrapper roll (e.g., a second end, as described herein, thereof) seated within the packing apparatus.

In some embodiments, a system provided herein comprises:

• • a raw material storage reservoir for containing raw material (e.g., of tobacco and/or cannabis leaf and/or flower, and/or herbs);
  • a gas packing apparatus comprising
    • a seating body configured to seat one or more pre-formed wrapper roll therewithin, and
    • a gas manifold configured to receive pressurized gas through at least one inlet and to expel pressurized gas (e.g., 1-100 psi) through one or more manifold outlet into one or more of the one or more pre-formed wrapper rolls seated within the seating body of the gas packing apparatus.

In specific embodiments provided herein is a system for manufacturing a cigarette, the system comprising:

• • an apparatus for reducing the average size of a raw material (e.g., whole or parts of tobacco and/or cannabis leaf and/or flower, and/or dried herbs) to produce raw material particles;
  • an apparatus configured to segregate raw material particles having a defined particle size from larger raw material bodies;
  • a raw material storage reservoir for containing segregated raw material particles having a defined particle size;
  • a wrapper storage apparatus for containing one or more pre-formed wrapper roll;
  • a loading apparatus comprising a loading body, the loading body having one or more loading bore therein (e.g., therethrough), the loading bore configured to receive one or more pre-formed wrapper roll therewithin, and the loading apparatus comprising a receiving surface configured to receive segregated raw material particles having a defined particle size from the raw material storage reservoir (e.g., and the loading apparatus further comprising a removable base upon which the one or more pre-formed wrapper roll rest when loaded within the loading bore, wherein removal of the removable base facilitates loading of one or more filled pre-formed wrapper roll into a gas packing apparatus);
  • a gas packing apparatus comprising
    • a seating body configured to seat one or more pre-formed wrapper roll therewithin, and
    • a gas manifold configured to receive pressurized gas (e.g., air) (e.g., 1-100 psi) through at least one inlet and to expel pressurized gas through one or more manifold outlet into one or more of the one or more pre-formed wrapper rolls seated within the seating body of the gas packing apparatus;
  • an apparatus configured to apply vibration to the loading apparatus; and
  • a physical packing apparatus configured to apply physical pressure to segregated raw material particles having a defined particle size that are contained within one or more pre-formed wrapper rolls seated within one or more bore of the loading apparatus.

In certain embodiments, a gas manifold herein is replaced with a vacuum manifold, such as wherein a vacuum manifold is configured to have a reduced pressure therein. In some instances, the vacuum manifold is configured to draw air or gas through a pre-formed wrapper roll seated within the seating body of a vacuum packing apparatus (e.g., and into the vacuum manifold), such as drawing air or gas through a first and second opening of a pre-formed wrapper roll seated within the seating body and into the vacuum manifold.

Particle Size

In some embodiments, the raw material is in the form of particles having a defined particle size. In specific embodiments, the raw material particles having a defined particle size have an average size (e.g., longest dimension) of about 5 mm or less (e.g., about 3 mm or less, or about 2 mm or less). In some embodiments, the raw material particles have an average size (e.g., longest dimension) of at least 0.05 mm, at least 0.1 mm, at least 0.2 mm, at least 0.5 mm, or the like.

Grinder

In certain embodiments, a system provided herein comprises an apparatus for reducing the average size of a raw material to produce raw material particles (e.g., having a size described herein). In some embodiments, the apparatus for reducing the average size of the raw material is configured to chop, grind, tear, and/or whip the raw material into smaller bodies.

Sifter

In some embodiments, a system provided herein comprises an apparatus configured to segregate raw material particles having a defined particle size from larger raw material bodies. In certain embodiments, the apparatus for segregating raw material particles having a defined particle size is a sieve (e.g., wherein the sieve mesh forms openings through which particles of a desired size fall through—the openings may be any shape and have any suitable aspect ratio). In some embodiments, the sieve is configured to shake or vibrate.

Wrapper Storage

In certain embodiments, a system provided herein comprises a wrapper storage apparatus, such as configured to contain one or more pre-formed wrapper roll. In specific embodiments, the wrapper storage comprises one or more hollow tube(s) (e.g., of any suitable shape, such as cylindrical, etc.), each hollow tube having a length or height sufficient to receive and store a plurality of pre-formed wrapper rolls therewithin. In more specific embodiments, the hollow tube of the wrapper storage comprises a receiving end configured to receive pre-formed wrapper rolls therethough and a dispensing end configured to dispense pre-formed wrapper rolls therethrough (e.g., delivering such pre-formed wrapper rolls into a loading apparatus).

In certain embodiments, a system provided herein comprises an gas manifold configured to receive pressurized gas (e.g., 1-25 psi) through at least one manifold inlet and to expel pressurized gas through one or more manifold outlet and into the receiving end of one or more hollow tube of the wrapper storage (e.g., thereby facilitating dispensing a pre-formed wrapper roll into a loading apparatus). In certain embodiments, a hollow tube of a wrapper storage provided herein comprises a body extending into the hollow tube, the body extending into the hollow tube at or in proximity to the dispensing end. In some instances, when providing pressurized gas into a hollow tube of a wrapper storage tube described herein, the pressure is sufficient to expel a single wrapper roll from the wrapper storage, with the body extending into the hollow tube preventing or inhibiting an additional wrapper roll configured within the hollow tube from also being expelled. In some instances, the body extending into the hollow tube comprises any suitable materials, such as a hard or flexible plastic material. In certain instances, the body extends into the hollow body to a sufficient degree such that the diameter of the hollow tube at the body extending into the hollow tube is equal to or less than the maximum diameter of the wrapper roll.

Packing Apparatus Seating Body

In some embodiments, a system provided herein comprises a (e.g., gas) packing apparatus, the (e.g., gas) packing apparatus comprising a seating body. In specific embodiments, the seating body comprises one or more bores therein (e.g., therethrough), each of the one or more bores comprising a first opening and a second opening. In some embodiments, the one or more bore is configured to receive one or more of the one or more pre-formed wrapper rolls (e.g., wherein each bore is configured to receive and/or seat one wrapper roll at a time). In specific embodiments, the (e.g., gas) packing apparatus is configured to receive the wrapper roll from a loading apparatus provided herein or from a wrapper storage apparatus provided herein. In certain embodiments, a bore (e.g., seating bore) of the (e.g., gas) packing apparatus is configured to receive a wrapper roll through the first or receiving opening and into the bore. In some embodiments, the seating bore is configured to seat and/or secure a pre-formed wrapper rolls therewithin. In preferred embodiments, a seating bore provided herein is in the shape of a conical frustum. In specific embodiments, the first (receiving) opening is larger than the second opening. In preferred embodiments, the first opening is of equal size or larger than the diameter or largest lateral dimension of a pre-formed wrapper roll secured or seated therein and the second opening is smaller than the diameter or largest lateral dimension of the pre-formed wrapper roll secured or seated therein. In some embodiments, the second opening is equal to or larger than the smallest diameter of the pre-formed wrapper roll seated or secured within the seating bore. In certain embodiments, the seating opening is equal to or larger than the diameter or largest lateral dimension of a crutch associated with the pre-formed wrapper roll seated or secured within the seating bore.

In certain embodiments, seating bore(s) are in the shape of a conical frustum. In specific embodiments, the first opening is larger than the second opening. In some embodiments, a conical shaped wrapper roll is utilized and seated within the seating bore, such as described herein. In certain embodiments, the seating bore has a bore apex angle and the conical wrapper roll has a wrapper apex angle. In specific embodiments, the bore apex angle is within 15 degrees of the wrapper apex angle. In more specific embodiments, the bore apex angle is within 10 degrees of the wrapper apex angle. In still more specific embodiments, the bore apex angle is within 5 degrees of the wrapper apex angle. In certain instances, good correlation between the bore apex angle and the wrapper apex angle facilitates good seating of the wrapper roll within the bore. Moreover, in some instances, good seating of the wrapper roll in the seating bore encourages gas flow through the wrapper roll, rather than around it. As discussed herein, gas flow through the wrapper roll (e.g., whether the gas flow is achieved by pressured gas and/or reduced pressure/vacuum) rather than around it facilitates good packing of the raw materials within the wrapper roll, removal of small particles, and provides other beneficial outcomes. For example, in some instances, if there is poor angle correlation between the wrapper roll and the seating bore, the air pressure may cause folding, ripping, or tearing of the wrapper paper, as the air pushes to get around the paper so that it may flow unencumbered around the wrapper roll, rather than pushing through and packing the raw materials within the wrapper roll. Similar effects may be observed in instances where a seating bore of an improper size is utilized. Thus, in some embodiments, when seated within a bore of a seating body, the exterior surface of the pre-formed wrapper roll is no more than 2 mm (e.g., no more than 1 mm, no more than 0.5 mm, no more than 0.3 mm, no more than 0.2 mm, or the like) from the interior surface of the apparatus bore (at its closest) at the first wrapper opening. In more preferred embodiments, when seated within a bore of a seating body, the exterior surface of the pre-formed wrapper roll is no more than 2 mm (e.g., no more than 1 mm, no more than 0.5 mm, no more than 0.3 mm, no more than 0.2 mm, or the like) from the interior surface of the apparatus bore (at its closest) at any point within the bore wherein the pre-formed wrapper roll is seated. As with use of a proper apex angle, in certain instances, a close seating of the wrapper roll within the seating bore forces the pressurized gas to flow into and through the wrapper roll, facilitating good packing of the raw materials.

Loading Apparatus

In certain embodiments, a system provided herein comprises a loading apparatus or an apparatus configured to receive one or more pre-formed wrapper roll and load, charge, or at least partially fill the one or more pre-formed wrapper rolls received therein with a raw material (e.g., raw material particles or segregated raw materials), such as described herein. In some instances, the system is configured such that pre-formed wrapper rolls are transferred from a wrapper storage to the loading apparatus. In certain embodiments, the system is configured such that once charged with raw materials (e.g., and following vibrational packing, such as wherein the loading apparatus is configures such that a vibrational force is or can be applied thereto), the loaded wrapper rolls are transferred from the loading apparatus to a (e.g., gas) packing apparatus, such as described herein. In other embodiments, the packing apparatus also functions as a loading apparatus described herein.

In some embodiments, a system provided herein comprises a loading body, the loading body having one or more loading bore therein, e.g., (completely) therethrough. In specific embodiments, the loading bore is configured to receive one or more pre-formed wrapper roll therewithin. In some embodiments, loading apparatus comprises a receiving surface configured to receive raw materials (e.g., raw material particles or segregated raw material particles) thereon. In specific embodiments, the raw materials are received from a raw material storage reservoir. In some embodiments, the receiving surface is configured to facilitate delivery of the raw materials from the receiving surface into the one or more pre-formed wrapper rolls seated within the loading apparatus.

In certain embodiments, the loading apparatus further comprises a removable base, such as upon which one or more pre-formed wrapper rolls rest when loading within the loading bores of the loading apparatus. In certain instances, the system comprises a loading apparatus and a (e.g., gas) packing apparatus, wherein one or more of the bores of the loading apparatus are aligned with one or more of the bores of the (e.g., gas) packing apparatus, with the removable base of the loading apparatus configured between the bores of the loading apparatus and the (e.g., gas) packing apparatus (e.g., thereby preventing any wrapper rolls loaded within the loading apparatus from falling or otherwise loading into the gas packing apparatus). In some instances, when the removable base of the (e.g., gas) packing apparatus is displaced from between the loading apparatus and the (e.g., gas) packing apparatus, the wrapper rolls (e.g., having been loaded in the loading apparatus) are transferred into the (e.g., gas) packing apparatus (e.g., and secured therein). More generally, in some instances, the loading apparatus comprises a removable base upon which the one or more pre-formed wrapper roll rest when loaded within the loading bore, wherein removal of the removable base facilitates loading of one or more filled pre-formed wrapper roll into a (e.g., gas) packing apparatus.

In certain instances, the (e.g., gas) packing apparatus and loading apparatus are configured into a single unit, wherein transfer between the two apparatuses is not necessary. In some such instances, wrapper roll(s) are seated within the (e.g., gas) packing apparatus, and are loaded and packed (e.g., with differential pressure (e.g., gas and/or vacuum) packing and optional vibrational and/or physical packing, such as described herein).

For clarity, in some embodiments, a loading apparatus and a gas packing apparatus utilized herein optionally utilize the same seating body for holding preformed wrapper rolls therein, while they are first loaded with raw material and second that raw material is packed therein. In other embodiments, a loading apparatus and a gas packing apparatus utilize different bodies for holding the preformed wrapper rolls therein (e.g., a first for holding the wrapper rolls while they are loaded with raw material and a second for holding (or seating) the wrapper rolls while the raw material is packed therein). In some embodiments, it is preferred to utilize a single seating body for both uses because it reduces the time spent handling of the preformed wrapper rolls, which can be fragile.

Gas/Vacuum Packing Apparatus Manifold

In certain embodiments, a system provided herein comprises one or more gas manifold. In some instances, a gas manifold comprises at least one inlet (e.g., through which pressurized gas or a gas flow is received) and at least one outlet (e.g., through which pressurized gas or a gas flow is expelled).

In certain embodiments, a system provided herein comprises one or more vacuum manifold. In some instances, a vacuum manifold comprises at least one inlet (e.g., through which a gas flow is drawn or received, such as through an opening of roll seated within a seating body described herein) and at least one outlet (e.g., through which reduced pressure is provided to the interior of the manifold, such as by attachment to a pump).

In certain embodiments, a system provided herein comprises a gas and/or vacuum manifold configured to interface with a gas packing apparatus, such as described herein. In some embodiments, the gas and/or vacuum manifold (e.g., one or more outlets thereof) is in proximity or is configured to be brought in proximity to one or more (e.g., first or receiving) opening(s) of the seating bore opening(s) (and/or wrapper openings of wrappers seated therein). In certain embodiments, the manifold outlet(s) are or are configured to be brought into contact with the seating bore opening(s), such that a seal or at least partial seal is formed therewith. More generally, in certain instances, one or more outlets of the gas manifold are configured to interface with some or all of the first opening(s) of the one or more of the bores of seating body. In some instances, one or more inlet of the vacuum manifold are configured to interface with some or all of the second opening(s) of the one or more of the bores of seating body.

In certain embodiments, a system provided herein comprises a (e.g., second) gas manifold configured to interface with a wrapper storage apparatus, such as described herein. In some embodiments, the (e.g., second) gas manifold (e.g., one or more outlets thereof) is in proximity or is configured to be brought in proximity to one or more (e.g., first or receiving) opening(s) of the wrapper storage (e.g., hollow tubes thereof). In certain embodiments, the (e.g., second) manifold outlet(s) are or are configured to be brought into contact with the hollow tube opening(s), such that a seal or at least partial seal is formed therewith. More generally, in certain instances, one or more outlets of the gas manifold are configured to interface with some or all of the first opening(s) of the one or more of the bores of seating body.

In some instances, a system provided herein comprises a vacuum manifold configured to interface with a wrapper storage apparatus (e.g., through a packing apparatus or loading apparatus described herein). In certain instances, a vacuum manifold of a system provided herein is configured to load wrapper rolls into a seating body and pack raw material into the wrapper roll after loading therein.

Any suitable gas can be used in a process, system or apparatus described herein. In specific embodiments, the gas is air, such as generated by a pump (which may form a part of the system provided herein). Other gases are optionally utilized as well, such as an inert gas, such as nitrogen, or gas mixtures (such as air and nitrogen). In some instances, the gas has a controlled humidity, such as at least 40% relative humidity (RH) (e.g., about 50% RH to about 60% RH).

Vibration Packing Apparatus

In certain embodiments, a system provided herein comprises an apparatus configured to apply vibration (e.g., speakers, tapping, etc.) to one or more apparatus of the system. In specific embodiments, a system provided herein comprises an apparatus configured to apply vibration (e.g., speakers, tapping, etc.) to a loading apparatus of a system described herein. In some embodiments, a system provided herein comprises an apparatus configured to apply vibration (e.g., speakers, tapping, etc.) to a (e.g., gas) packing apparatus of a system described herein.

Physical Packing Apparatus

In some embodiments, a system provided herein comprises a physical packing apparatus configured to apply physical pressure to raw materials that are contained within one or more pre-formed wrapper rolls. In specific embodiments, a physical packing apparatus is configured to apply physical pressure to raw materials that are contained within one or more pre-formed wrapper rolls seated within one or more bore of the loading apparatus. In certain embodiments, a physical packing apparatus is configured to apply physical pressure to raw materials that are contained within one or more pre-formed wrapper rolls seated within one or more bore of the (e.g., gas) packing apparatus. In some instances, a physical packing apparatus comprises a dowel and/or piston configured to press into the bores of a loading and/or (e.g., gas) packing apparatus, such as provided herein.

In certain instances herein, processes, systems and apparatuses are described. It is to be understood that any description of a method having a certain step is intended to disclose a corresponding apparatus or system configured to perform such action. Similarly, any description of an apparatus or system configured to perform a particular task is understood as also describing a process step of performing such a task. Moreover, any system or apparatus described herein is understood to be used or usable in a process herein. In addition, reference to “a” or “one” of any item described herein is understood to disclose each of one and only one of such item, one or more of such item, or more than one of such item. Similarly, reference to “at least one” or “one or more” is understood to disclose each of one and only one, one or more of such item, or more than one of such item.

Headings are included throughout the disclosure herein. Such headings are intended for organizational purposes only and do not limit the disclosure herein in any manner.

Systems, apparatuses, and processes are described herein. Description of processes herein are intended to also describe apparatuses and systems comprising devices described therein, e.g., and configured to achieve the process and/or process steps described. Description of systems and apparatuses are also intended to be described as being used in the processes herein and used to achieved the process and/or process steps described.

INCORPORATION BY REFERENCE

All publications, patents, and patent applications mentioned in this specification are herein incorporated by reference to the same extent as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated by reference.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an exemplary gas packing apparatus provided herein.

FIG. 2 illustrates another angle and close up view of an exemplary gas packing apparatus provided herein.

FIG. 3 illustrates an exemplary gas manifold provided herein for packing raw material within a wrapper roll.

FIG. 4 illustrates an exemplary gas manifold in association or proximity with a gas packing apparatus, such as to provide a pressurized gas or gas flow into and through a gas packing apparatus, in particular, the bores thereof.

FIG. 5 illustrates an exemplary conical wrapper roll provided herein.

FIG. 6 illustrates an exemplary conical wrapper roll loaded into an exemplary gas packing apparatus provided herein.

FIG. 7 illustrates a cross section of an exemplary alternate seating body structure of a gas packing apparatus provided herein.

DETAILED DESCRIPTION OF THE INVENTION

In certain instances, provided herein are processes, apparatuses, systems, and products thereof. In specific instances, provided herein are processes, apparatuses, systems suitable and/or capable of producing cigarettes (e.g., including tobacco cigarettes, cannabis cigarettes (also known as cannabis “pre-rolls”), and other enlongated smokable objects, such as objects suitable for drug delivery via smoking). Products provided herein, and as made possible using the processes, systems, and apparatuses described herein, are uniquely capable of being utilized for a broad range of raw materials, including those that are fluffy, sticky, high-resin content, and/or are generally difficult to process. Such raw materials include, by way of non-limiting example, tobacco products, cannabis products, herb products and the like. Cannabis products include, by way of non-limiting examples, those with high (e.g., greater than 0.5 wt. %) cannabidiol (CBD), tetrahydrocannabinol (THC), and/or other cannabinoid content.

In some instances, products according to the instant disclosure and produceable thereby include products those that highly consistent and uniform throughout the product. In certain instances such products have good and uniform packing of raw materials therein. A primary concern of packing difficult to pack raw materials (e.g., fluffy, sticky, and/or high resin materials) is that it is extremely difficult to achieve good and consistent packing of the raw material at the base of the cigarette (i.e., the end near the crutch or away from the loading opening or near the end that is inserted into the mouth of a user). In certain instances, such poor packing ultimately leads to poor packing throughout the product as the raw materials settle and the packing density somewhat homogenizes. In some instances, the result is an inferior product that the burns unevenly, runs, canoes, or the like. Moreover, in certain instances, inconsistent packing throughout the product causes inconsistent burning and can make it difficult to pull or draw air through the product while using. By contrast, in certain instances herein, products provided herein have a uniform pack density throughout the product, including proximal to the crutch or mouthpiece thereof and/or distal to the loading end of thereof.

Also, illustrated in the figures herein are are representative and non-limiting examples of certain components described herein.

FIG. 1 illustrates an exemplary seating body 100 portion of a gas packing apparatus provided herein. As illustrated, the seating body 100 comprises a body 101 portion, with a plurality of bores 102 (seating bores) configured through the body 101 portion of the seating body 100. In some instances, the seating bores 102 have a first opening 103 and a second opening 104 (not shown, but configured distal to the first opening 103). In some embodiments, a pre-formed wrapper roll is loaded into a seating bore 102 through. FIG. 2 illustrates another angle and close up view of an exemplary seating body 100 of the gas packing apparatus. As illustrated, the exemplary seating body 100 comprises a plurality of seating bores 102, each seating bore with a first opening 103 and a second opening 104. As illustrated, the seating bore 102 has a conical configuration, with the first opening 103 being larger than the second opening 104. As discussed herein, such a configuration allows for a close association between a conical wrapper roll and the inner surface of the seating bore 102.

FIG. 3 illustrates an exemplary gas manifold portion of a gas packing apparatus (or system) provided herein. In some instances, the gas packing apparatus comprises a gas manifold system 303 comprising a manifold outlet body 300 and seating body 100, such as wherein the manifold outlet body 300 is configured to interface with the seating body 100, such as illustrated in FIG. 4. As illustrated in the exemplary gas manifold outlet body 300, the gas manifold outlet body comprises at least one inlet 301, to which pressurized gas is provided (e.g., via a tube from a gas manifold body, such as illustrated). Further, as illustrated the exemplary gas manifold outlet body 300 comprises a plurality of manifold outlets 302. In some instances, a manifold or manifold system 303 provided herein comprises a manifold body 304 comprising an inlet (not shown), such as connected to a pressurized gas source (not shown), and one or more outlet 305. In some instances, the one or more outlet 305 of the manifold body 304 is connected (e.g., by a connector 306, such as piping or tubing) to one or more inlet 301 of a manifold outlet body 300, such as wherein the manifold outlet body 300 has one or more inlet 301 connected to one or more outlet 302, such as wherein the one or more outlet 302 is configured to interface with one or more bore (e.g., opening thereof) of a seating body described herein. In certain embodiments, a manifold body 304 comprises one or more outlet 305, with a pressure gauge 307 connected thereto. In some instances, such a pressure gauge facilitates quality control of the gas being provided into a corresponding bore of a seating body associated therewith. In other instances, the manifold and the manifold outlet body are integrated into a single body, such as wherein the manifold comprises an inlet and one or more outlet, such as wherein the one or more outlet is configured to interface with one or more bore (e.g., opening thereof) of a seating body described herein. For the avoidance of confusion, a manifold described herein may refer to either a manifold system 303 or a manifold outlet body 300, as long as the requirements described for the manifold are satisfied, such as comprising at least one inlet (xxx or 301) and at least one outlet 302. FIG. 4 illustrates how the manifold outlets 302 are brought into proximity with the bore opening(s) 103.

In some embodiments, an outlet of a manifold provided herein comprises a sealing body configured therearound. In certain embodiments, the sealing body is any shape and made of any suitable material (e.g., plastic, rubber, or the like) to facilitate providing a good seal at the manifold outlet and seating bore junction. In some embodiments, the sealing body 308 comprises a surrounding body 309, the surrounding body 309 surrounding the outlet 302, and configured to seat around an opening of a seating bore of a seating body described herein (e.g., as illustrated in FIG. 4 and FIG. 6). In further or alternative embodiments, the sealing body 308 comprises a protruding portion 310, such that the protruding portion 309 is configured to seat within a seating bore of a seating body described herein (e.g., as illustrated in FIG. 6).

FIG. 5 illustrates an exemplary conical wrapper roll 500 provided herein. The illustrated wrapper roll has an overall length 501. In addition, the illustrated wrapper roll comprise wrapper material 502 and a crutch 503 configured within the wrapper roll 501. The crutch 503 has a length 504. As discussed herein, in certain embodiments, when seated within a seating body of a gas packing apparatus, the wrapper extends beyond the second opening of the gas packing apparatus by a length of at least the length of the crutch 504. Moreover, in certain embodiments, the entirety of the wrapper body passes through the first opening of the seating bore, indicating that the length of the bore is, in some instances, no greater than the length 505 of the wrapper roll that excludes the crutch 503. In some embodiments, processes and apparatuses provided herein comprise or are configured to provide pressurized gas (and raw materials) into a first (e.g., larger or receiving) opening 506 of a wrapper roll 500. As illustrated, in certain embodiments, the pre-formed wrapper roll 500 further comprises a second (e.g., smaller) opening 507, the second opening 507 having a crutch 503, such as a rolled paper or filter, configured in proximity thereof. In certain embodiments, the pre-formed wrapper roll 500 comprises a wrapper material 502 configured in a rolled (e.g., cylindrical or conical) shape and having an interior surface defining an interior space, the crutch 503 being configured within the interior space and in proximity to the second (e.g., smaller, such as in a conical configuration) opening 507. In certain embodiments, the process comprises applying pressurized gas to the first opening 506 of the pre-formed wrapper roll 500, such pressurized gas flowing into the pre-formed wrapper roll 500 and out of the second opening 507 of the pre-formed wrapper roll 507. In some embodiments, the wrapper roll 500 comprises a crutch 503 in proximity to the second opening 507, the crutch comprising sufficient void space (e.g., is sufficiently porous) therein to allow pressurized gas to flow therethrough. FIG. 6 illustrates the gas flowing into a preformed wrapper roll 605 loaded into a seating bore 602.

FIG. 6 illustrates a cross section of an exemplary seating body 600 portion of a gas packing apparatus provided herein. As illustrated, the seating body 600 comprises a seating bore 602 configured through the seating body 600. In some instances, the seating bore 602 has a first opening 603 and a second opening 604. FIG. 6 also illustrates a pre-formed wrapper roll 605 loaded into a seating bore 602. As illustrated, the seating bore 602 has a conical (conical frustum) configuration, with the first opening 603 being larger than the second opening 604. As discussed herein, such a configuration allows for a close association between a conical wrapper roll 605 and the inner surface of the seating bore 602.

As illustrated in FIG. 6, in some instances, the entirety of a crutch 606 of a pre-formed wrapper roll 605 is configured completely outside of the seating bore 602. In other words, in some instances, the crutch 606 is passed completely through the seating bore 602 or the crutch extends beyond the second bore opening 604 in its entirety. As discussed herein, a significant difficulty in packing fluffy, stick, and/or high-resin raw materials (e.g., cannabis, such as hemp) is associated with a difficulty to achieve good uniformity in the pack at the end of the wrapper roll distal to the receiving end of the wrapper roll. In some instances, by configuring the crutch completely outside of the seating bore when packing, a tight packing is facilitated at or near the crutch (e.g., wrapped and/or rolled paper and/or filter). In certain instances, such configurations provide good overall packing within the cigarette. Other processes (particularly on a commercial scale) generally provide loose packing distal to the receiving end of the wrapper roll, leading to a loose overall pack as the raw materials settle. As such, in certain instances, good distal packing facilitates good overall packing over time of the cigarette, leading to good performance and burn of the cigarette when ultimately utilized (e.g., by a person in need thereof). In specific embodiments, the entirety of the crutch 606 extends beyond the seating bore 602, as well as an additional portion of the wrapper roll 607. In specific embodiments, the crutch extends beyond the seating bore by at least 0.1 mm (e.g., at least 0.2 mm, at least 0.5 mm, at least 1 mm, at least 2 mm, at least 3 mm, or the like). In other words, in some instances, when seated, the entirety of the crutch, plus an additional amount 607 protrudes from the second seating bore opening.

FIG. 6 also illustrates a manifold outlet 608 interfacing with a first opening 603 of the seating bore 602. As illustrated, pressurized gas (e.g., air) is provided (i) into the seating bore 602, through the first opening thereof 603, and into the first opening 609 of the pre-formed wrapper roll 605 and (ii) out of the seating bore 602, through the second opening thereof 604, and out of the second opening 610 of the pre-formed wrapper roll 605. As illustrated, around the manifold outlet 608 is a sealing body 609, which may have any suitable shape and made of any suitable material (e.g., plastic, rubber, or the like) such as to facilitate providing a good seal at the manifold outlet and seating bore junction. In some embodiments, the sealing body 609 comprises a surrounding body 610, the surrounding body 610 surrounding the outlet 608, and configured to seat around an opening of a seating bore 603 of a seating body described herein. In further or alternative embodiments, the sealing body 609 comprises a protruding portion 611, such that the protruding portion 611 is configured to seat within a seating bore 602 of a seating body described herein.

In some instances, a seating bore extends at least partially through a seating body provided herein. For example, FIG. 7 illustrates a cross section of a seating body 700 comprising a seating bore 701 configured therethrough. In the example of FIG. 7, the base 702 is indented at the second opening 703 of the seating bore 701, however, such that the second opening 703 of the seating bore 703 is not flush with the distal-most portion of the seating body base 702. In some instances, such a configuration may be preferred when it is desired to protect the crutch of a pre-formed wrapper roll (not shown), such that it does not extend outside the protective area of the seating body 700.

EXAMPLES

Example 1

Provide raw material (hemp cannabis). Measure humidity and moisture. Run raw material through grinding (whipping) process to separate stems from flower and create initial grind. Sift initial grind to further separate stems and obtain a homogenized particle size. Select pre-formed wrapper roll cone configuration and the appropriate loading apparatus (i.e., corresponding to the size and shape of the pre-formed wrapper rolls). Load wrapper rolls into loading apparatus. Charge wrapper rolls with selected mass and/or volume of homogenized raw material particles. Transfer filled wrapper rolls from loading apparatus into gas packing apparatus (chambers or bores thereof). Gas is injected directly into the top of the wrapper roll cone at 40-50 psi to create a pressure within the loaded wrapper roll. Backpressure escapes through the hole in the bottom of the wrapper roll cone. Remove packed pre-rolls from gas packing apparatus chambers. Twist the top of the paper, inspect and finish. Products produced are firm and uniform along the length of the product, as compared to comparative products that lack firmness (particularly near the cone apex or crutch configured near the cone apex) and have inconsistent firmness along the length of the product.

Example 2

Provide raw material (hemp cannabis). Measure humidity and moisture. Run raw material through grinding (whipping) process to separate stems from flower and create initial grind. Sift initial grind to further separate stems and obtain a homogenized particle size. Select pre-formed wrapper roll cone configuration and the appropriate seating body (i.e., corresponding to the size and shape of the pre-formed wrapper rolls). Load wrapper rolls into seating body. Charge wrapper rolls with selected mass and/or volume of homogenized raw material particles. Gas is injected directly into the top of the wrapper roll cone at 40-50 psi to create a pressure within the loaded wrapper roll. Backpressure escapes through the hole in the bottom of the wrapper roll cone. Remove packed pre-rolls from gas packing apparatus chambers. Twist the top of the paper, inspect and finish.

Claims

1. A system for manufacturing a cigarette, the system comprising:

an apparatus for reducing the average size of a raw material (e.g., whole or parts of tobacco and/or cannabis leaf and/or flower, and/or dried herbs) to produce raw material particles;

an apparatus configured to segregate raw material particles having a defined particle size from larger raw material bodies;

a raw material storage reservoir for containing segregated raw material particles having a defined particle size;

a wrapper storage apparatus for containing one or more pre-formed wrapper roll;

a loading apparatus comprising a receiving surface configured to receive segregated raw material particles having a defined particle size from the raw material storage reservoir (e.g., and the loading apparatus further comprising a removable base upon which the one or more pre-formed wrapper roll rest when loaded within the loading bore, wherein removal of the removable base facilitates loading of one or more filled pre-formed wrapper roll into a gas packing apparatus);

a gas packing apparatus comprising a seating body, seating body having one or more seating bore therein (e.g., therethrough), the seating bore configured to receive one or more pre-formed wrapper roll therewithin, and a gas manifold configured to receive pressurized gas (e.g., air) (e.g., 1-100 psi) through at least one inlet and to expel pressurized gas through one or more manifold outlet into one or more of the one or more pre-formed wrapper rolls seated within the seating body of the gas packing apparatus;

an apparatus configured to apply vibration to the loading apparatus; and

a physical packing apparatus configured to apply physical pressure to segregated raw material particles having a defined particle size that are contained within one or more pre-formed wrapper rolls seated within one or more bore of the loading apparatus.

2. A system for manufacturing a cigarette, the system comprising:

a gas packing apparatus comprising a seating body, seating body having one or more seating bore therein (e.g., therethrough), the seating bore configured to receive one or more pre-formed wrapper roll therewithin, and a gas manifold system configured to receive pressurized gas (e.g., air) (e.g., 1-100 psi, such as about 20 psi to about 50 psi) through at least one manifold inlet and to expel pressurized gas (i) through one or more manifold outlet and (ii) into one or more of the one or more of the seating bores of the seating body.

3. A system for manufacturing a cigarette, the system comprising:

an apparatus for reducing the average size of a raw material (e.g., whole or parts of tobacco and/or cannabis leaf and/or flower, and/or dried herbs) to produce raw material particles;

an apparatus configured to segregate raw material particles having a defined particle size from larger raw material bodies;

a wrapper storage apparatus for containing one or more pre-formed wrapper roll (e.g., wherein the wrapper storage apparatus is configured to load the pre-formed wrapper roll(s) into the seating body); and

a gas packing apparatus comprising a seating body, seating body having one or more seating bore therein (e.g., therethrough), the seating bore configured to receive one or more pre-formed wrapper roll therewithin, and a gas manifold system configured to receive pressurized gas (e.g., air) (e.g., 1-100 psi, such as about 20 psi to about 50 psi) through at least one manifold inlet and to expel pressurized gas (i) through one or more manifold outlet and (ii) into one or more of the one or more of the seating bores of the seating body; and

an apparatus configured to apply vibration to the loading apparatus.

4. A system for manufacturing a cigarette (e.g., tobacco or cannabis), the system comprising:

a raw material storage reservoir for containing raw material particles (e.g., of tobacco and/or cannabis leaf and/or flower, and/or herbs);

a vacuum packing apparatus comprising a seating body configured to seat one or more pre-formed wrapper roll therewithin, and a vacuum manifold comprising one or more vacuum manifold inlet, the one or more vacuum manifold inlet configured (i) receive reduced pressure (e.g., <1 atm) therein; and (ii) to draw air or gas through one or more pre-formed wrapper roll seated within the seating body of the vacuum packing apparatus and into the one or more vacuum manifold inlet.

5. The system of any one of the preceding claims, wherein the raw material particles have a defined particle size.

6. The system of any one of the preceding claims, wherein the raw material particles having a defined particle size have an average size (e.g., longest dimension) of about 5 mm or less (e.g., about 3 mm or less, or about 2 mm or less).

7. The system of any one of the preceding claims, further comprising an apparatus for reducing the average size of a raw material to produce raw material particles.

8. The system of any one of the preceding claims, wherein the apparatus for reducing the average size of the raw material is configured to chop, grind, tear, and/or whip the raw material into smaller bodies.

9. The system of any one of the preceding claims, further comprising an apparatus configured to segregate raw material particles having a defined particle size from larger raw material bodies.

10. The system of any one of the preceding claims, wherein the apparatus for segregating raw material particles having a defined particle size is a sieve (e.g., wherein the sieve mesh forms openings through which particles of a desired size fall through—the openings may be any shape and have any suitable aspect ratio).

11. The system of any one of the preceding claims, wherein the sieve is configured to shake or vibrate.

12. The system of any one of the preceding claims, further comprising a wrapper storage apparatus for containing one or more pre-formed wrapper roll.

13. The system of any one of the preceding claims, wherein the wrapper storage comprises one or more hollow body(s) (e.g., of any suitable shape, such as cylindrical, etc.), each hollow tube having a length or height sufficient to receive and store a plurality of pre-formed wrapper rolls therewithin.

14. The system of any one of the preceding claims, wherein the hollow body of the wrapper storage comprises a receiving end configured to receive pre-formed wrapper rolls therethough and a dispensing end configured to dispense pre-formed wrapper rolls therethrough (e.g., delivering such pre-formed wrapper rolls into a loading apparatus).

15. The system of any one of the preceding claims, further comprising an gas manifold configured to receive pressurized gas through at least one manifold inlet and to expel pressurized gas through one or more manifold outlet and into the receiving end of one or more hollow tube of the wrapper storage (e.g., thereby facilitating dispensing a pre-formed wrapper roll into a loading apparatus).

16. The system of any one of the preceding claims, wherein the seating body comprises one or more bores therethrough, each of the one or more bores comprising a first opening and a second opening, the one or more bore being configured to receive one or more of the one or more pre-formed wrapper rolls (e.g., from the wrapper storage apparatus) through the first opening and into the bore, and the one or more bore being configured to secure the one or more of the one or more one or more pre-formed wrapper rolls therewithin.

17. The system of any one of the preceding claims, wherein each of the one or more bores configured to receive and secure no more than one pre-formed wrapper at any given time.

18. The system of any one of the preceding claims, wherein the one or more bores of seating body are in the shape of a conical frustum (e.g., wherein the first opening is larger than the second opening).

19. The system of any one of the preceding claims, wherein the pre-formed wrapper roll has a conical or cylindrical (or other suitable three-dimensional) configuration.

20. The system of any one of the preceding claims, wherein the one or more bores of seating body are in the shape of a conical frustum, wherein the first opening is larger than the second opening, and wherein the apex angle of the bore is within 10 degrees (e.g., within 5 degrees) of the apex angle of the pre-formed wrapper roll.

21. The system of any one of the preceding claims, wherein the receiving surface is configured to facilitate delivery of the segregated raw material particles having a defined particle size from the receiving surface into the one or more pre-formed wrapper rolls seated within the loading apparatus.

22. The system of any one of the preceding claims, wherein the one or more outlets of the gas manifold are configured to interface with some or all of the first opening(s) of the one or more of the bores of seating body.

23. The system of any one of the preceding claims, further comprising an apparatus configured to apply vibration (e.g., speakers, tapping, etc.) to the loading apparatus.

24. The system of any one of the preceding claims, further comprising a packing apparatus configured to apply physical pressure to segregated raw material particles having a defined particle size that are contained within one or more pre-formed wrapper rolls seated within one or more bore of the loading apparatus

25. A method for manufacturing a cigarette, the method comprising:

reducing the average size of a raw material (e.g., whole or parts of tobacco and/or cannabis leaf and/or flower) to produce raw material particles;

separating raw material particles having a defined particle size from larger raw material bodies to provide segregated raw material particles;

stocking a raw material storage reservoir with the segregated raw materials particles;

providing a a wrapper storage apparatus stocked with a plurality of pre-formed wrapper rolls;

loading the plurality of seated, pre-formed wrapper rolls with the segregated raw materials particles;

applying vibration to the plurality of loaded wrapper rolls;

seating a seating body of a gas packing apparatus with a plurality of pre-formed wrapper rolls (e.g., transferring such pre-formed wrapper rolls from the wrapper storage apparatus to the loading apparatus if loading is done in the gas packing apparatus, or transferring the plurality of loaded wrapper rolls to the gas packing apparatus if loaded by hand or using a loading apparatus);

gas packing the segregated raw materials particles in the plurality of loaded wrapper rolls by applying pressurized gas (e.g., 1-100 psi) thereto; and

physically packing the segregated raw materials particles in the plurality of loaded wrapper rolls.

26. A method for manufacturing a cigarette, the method comprising:

loading a plurality of pre-formed wrapper rolls with raw materials particles to form a plurality of loaded wrapper rolls;

seating a gas packing apparatus (e.g., seating body thereof) with a plurality of pre-formed wrapper rolls (e.g., transferring such pre-formed wrapper rolls from a wrapper storage apparatus to the gas packing apparatus if loading is done in the gas packing apparatus, or transferring the plurality of loaded or filled pre-formed wrapper rolls to the gas packing apparatus if loaded by hand or using a loading apparatus); and

packing the raw materials particles in the plurality of loaded wrapper rolls by applying pressurized gas (e.g., 1-100 psi) thereto (e.g., a first opening thereof).

27. A method for manufacturing a cigarette, the method comprising:

loading a plurality of pre-formed wrapper rolls with raw materials particles to form a plurality of loaded wrapper rolls;

seating a vacuum packing apparatus with a plurality of pre-formed wrapper rolls (e.g., transferring such pre-formed wrapper rolls from a wrapper storage apparatus to the gas packing apparatus if loading is done in the gas packing apparatus, or transferring the plurality of loaded or filled pre-formed wrapper rolls to the gas packing apparatus if loaded by hand or using a loading apparatus); and

packing the raw materials particles in the plurality of loaded wrapper rolls by applying reduced pressure thereto (e.g., a second opening thereof).

28. The method of any of the preceding claims, wherein the raw materials comprise whole or parts of tobacco and/or cannabis leaf and/or flower.

29. The method of any of the preceding claims, further comprising reducing the average size of a raw material to produce raw material particles.

30. The method of any of the preceding claims, further comprising reducing the average size of the raw material by chopping, grinding, tearing, and/or whipping the raw material into smaller bodies.

31. The method of any of the preceding claims, wherein the raw material particles have a defined particle size.

32. The method of any of the preceding claims, wherein the raw material particles having a defined particle size have an average size (e.g., longest dimension) of about 5 mm or less (e.g., about 3 mm or less, or about 2 mm or less).

33. The method of any of the preceding claims, further comprising stocking a raw material storage reservoir with the segregated raw materials particles.

34. The method of any of the preceding claims, further comprising separating raw material particles having a defined particle size from larger raw material bodies to provide segregated raw material particles.

35. The method of any of the preceding claims, wherein separating the raw material particles having a defined particle size from larger raw material bodies comprises sifting the particles through a sieve mesh.

36. The method of any of the preceding claims, wherein separating the raw material particles having a defined particle size from larger raw material bodies comprises placing the particles on a sieve mesh and shaking or vibrating the sieve mesh.

37. The method of any one of the preceding claims, wherein the pre-formed wrapper rolls comprise a crutch a wrapper material.

38. The method of any one of the preceding claims, wherein the crutch facilitates holding of the wrapper material in the configuration of the pre-formed wrapper roll.

39. The method of any one of the preceding claims, wherein the pre-formed wrapper rolls are in a cylindrical or conical shape.

40. The method of any one of the preceding claims, wherein the pre-formed wrapper rolls are in the shape of a cone.

41. The method of any one of the preceding claims, wherein the pre-formed wrapper rolls have a first end and a second end, the first end being open to the interior of a three-dimensional structure defined by a wrapper material.

42. The method of any one of the preceding claims, wherein the pre-formed wrapper rolls have a first end and a second end, the first end having a first opening to the interior of a three-dimensional structure defined by a wrapper material, and the second end (e.g., the apex in a conical shape) having a second opening to the interior of the three-dimensional structure, the second opening being smaller than the first opening (e.g., with a rolled or folded paper crutch configured within the interior structure in proximity to the second end).

43. The method of any one of the preceding claims, wherein the pre-formed wrapper rolls have a first end and a second end, the first end having a first opening to the interior of a three-dimensional structure defined by a wrapper material, and a porous filter body being configured within the interior structure in proximity the second end.

44. The method of any one of the preceding claims, wherein the wrapper material comprises paper and/or tobacco and/or cannabis leaf.

45. The method of any of the preceding claims, further comprising stocking a wrapper storage apparatus with a plurality of pre-formed wrapper rolls.

46. The method of any of the preceding claims, wherein the wrapper storage comprises one or more hollow tube(s) (e.g., of any suitable shape, such as cylindrical, etc.), each hollow tube having a length or height sufficient to receive and store a plurality of pre-formed wrapper rolls therewithin.

47. The method of any of the preceding claims, wherein the hollow tube of the wrapper storage comprises a receiving end configured to receive pre-formed wrapper rolls therethough and a dispensing end configured to dispense pre-formed wrapper rolls therethrough (e.g., delivering such pre-formed wrapper rolls into a loading apparatus).

48. The method of any of the preceding claims, further comprising applying a pressurized gas to the receiving end of one or more hollow tube of the wrapper storage (e.g., thereby facilitating dispensing a pre-formed wrapper roll into a loading apparatus).

49. The method of any one of the preceding claims, wherein the plurality of pre-formed wrapper rolls are loaded with raw materials (e.g., 0.2 to 5 g of raw materials, depending on the size of the pre-formed wrapper roll).

50. The method of any one of the preceding claims, wherein the plurality of pre-formed wrapper rolls are loaded with raw materials are loaded with a pre-determined volume of raw materials.

51. The method of any one of the preceding claims, wherein the pre-determined volume of raw materials is determined by measuring the volume of a known mass of raw materials (e.g., different raw materials have different densities).

52. The method of any one of the preceding claims, wherein (e.g., prior to loading) the one or more of the plurality of pre-formed wrapper rolls is loaded into a loading apparatus, the loading apparatus comprising a loading body, the loading body having one or more loading bore therethrough, the one or more of the plurality of pre-formed wrapper rolls being loaded into the plurality one or more loading bore.

53. The method of any one of the preceding claims, wherein the loading apparatus further comprises a receiving surface, and the process comprising charging the receiving surface with raw material particles (e.g., from a raw material storage reservoir).

54. The method of any of the preceding claims, further comprising applying vibration (e.g., by tapping, using speakers, or the like) to the plurality of loaded wrapper rolls.

55. The method of any one of the preceding claims, further comprising applying vibration to the seated, loaded pre-formed wrapper roll (e.g., facilitating a (e.g., preliminary) packing of the raw material particles into the pre-formed wrapper roll).

56. The method of any one of the preceding claims, further comprising transferring loaded pre-formed wrapper rolls to a gas packing apparatus (e.g., wherein the loading apparatus further comprises a removable base upon which the one or more pre-formed wrapper roll rest when loaded within the loading bore, and the process further comprising removal of the removable base facilitating transfer of the one or more filled pre-formed wrapper roll into a gas packing apparatus).

57. The method of any one of the preceding claims, wherein the gas packing apparatus comprises a seating body, the seating body comprising a plurality of bores therethrough into which the pre-formed wrapper rolls are seated.

58. The method of any one of the preceding claims, wherein the bores of the seating body each comprise a first bore opening and a second bore opening, the pre-formed wrapper rolls being loaded into the bore through the first bore opening and seated within the bore.

59. The method of any one of the preceding claims, wherein the bores of the seating body each comprise a first bore opening and a second bore opening, the pre-formed wrapper rolls having a first end and a second end, the first end being passed through the first and then second bore openings before being seated within the bore.

60. The method of any one of the preceding claims, wherein the pre-formed wrapper rolls each comprise a first end and a second end, the pre-formed wrapper rolls having a first end and a second end, the first end having a first wrapper opening to the interior of a three-dimensional structure defined by a wrapper material, and the second end (e.g., the apex in a conical shape) having a second wrapper opening to the interior of the three-dimensional structure, the second wrapper opening being smaller than the first wrapper opening, wherein a (e.g., rolled or folded paper) crutch or porous filter is configured within the interior structure of the pre-formed wrapper roll in proximity to the second end, and wherein the entirety of the crutch or porous filter is outside of the bore (i.e., extended beyond the second bore opening) (e.g., facilitating tight packing at or near the filter or crutch, providing an overall good, uniform packing in the final product).

61. The method of any one of the preceding claims, wherein the entirety of the crutch or porous filter is at least 0.5 mm (e.g., at least 1 mm, at least 2 mm, at least 3 mm, or the like) outside of the bore (i.e., when seated, the entirety of the crutch or filter, plus an additional amount protrudes from the second bore opening).

62. The method of any one of the preceding claims, wherein the pre-formed wrapper roll has a conical configuration and the bore has a conical configuration (e.g., a conical frustrum), and wherein the pre-formed wrapper roll has a conical configuration has an apex angle that is within 10 degrees (e.g., within 5 degrees, within 3 degrees, or the like) of an apex angle of the bore conical configuration (e.g., facilitating packing by ensuring gas flow through the pre-formed wrapper roll, rather than around it).

63. The method of any one of the preceding claims, wherein the pre-formed wrapper rolls each have an exterior surface and the loading apparatus bores have an interior surface, and wherein when seated, the exterior surface of the pre-formed wrapper roll is no more than 2 mm (e.g., no more than 1 mm, no more than 0.5 mm, or the like) from the interior surface of the apparatus bore (at its closest) (e.g., at any point within the bore wherein the pre-formed wrapper roll is seated, at the first wrapper opening, or both) (e.g., facilitating packing by ensuring gas flow through the pre-formed wrapper roll, rather than around it).

64. The method of any one of the preceding claims, wherein each of the one or more bores receive no more than one pre-formed wrapper roll (e.g., at any given time).

65. The method of any one of the preceding claims, wherein gas packing the raw materials particles in the plurality of loaded wrapper rolls by providing pressurized gas (e.g., 1-100 psi, such as measured in line prior to expulsion into an opening described herein, such as through a gas manifold described herein) into the first wrapper opening.

66. The method of any one of the preceding claims, gas packing the raw materials particles in the plurality of loaded wrapper rolls by providing pressurized gas (e.g., 1-100 psi) into the first bore opening.

67. The method of any one of the preceding claims, wherein the pressurized gas flows into the bore through a first bore opening and out of the bore through a second bore opening.

68. The method of any one of the preceding claims, wherein the pressurized gas flows into the wrapper roll through a first wrapper opening and out of the wrapper roll through a second wrapper opening (e.g., facilitating good packing without adverse effects when the pressure is removed due to back pressure effects, and/or facilitating removal of too small particles that would otherwise be consumed or inhaled by a user).

69. The method of any one of the preceding claims, wherein gas packing the raw materials particles in the plurality of loaded wrapper rolls by providing pressurized gas to at least one inlet of a gas manifold, and bringing at least one outlet of the gas manifold in proximity to (e.g., in contact with, such as forming at least a partial seal with) at least one (e.g., multiple) (first) bore opening(s).

70. The method of any of the preceding claims, further comprising physically packing (e.g., with a dowel and/or piston) the raw materials particles in a plurality of loaded wrapper rolls (e.g., seated within the bores of loading apparatus).

71. The method of any one of the preceding claims, further comprising applying an additive to an external surface of the wrapper material (e.g., by spraying, dipping, painting, or other method an additive (e.g., oil) or a solution or suspension thereof).

72. The method of any one of the preceding claims, further comprising twisting and/or removing a portion of or the first end of the wrapper material (e.g., a portion that extends (e.g., in the direction of the first end or opening) beyond the packed raw material particles within the pre-formed wrapper roll).