Classifications

• • A—HUMAN NECESSITIES
  • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
  • A24B—MANUFACTURE OR PREPARATION OF TOBACCO FOR SMOKING OR CHEWING; TOBACCO; SNUFF
  • A24B3/00—Preparing tobacco in the factory
  • A24B3/18—Other treatment of leaves, e.g. puffing, crimpling, cleaning
  • A24B3/182—Puffing
  • A24B3/185—Puffing by impregnating with a liquid and subsequently freezing and evaporating this liquid
• • A—HUMAN NECESSITIES
  • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
  • A24B—MANUFACTURE OR PREPARATION OF TOBACCO FOR SMOKING OR CHEWING; TOBACCO; SNUFF
  • A24B3/00—Preparing tobacco in the factory
  • A24B3/12—Steaming, curing, or flavouring tobacco

Definitions

• the present invention relates to a process and in particular a process for the production of dry ice expanded botanical material, such as dry ice expanded tobacco (DIET).
• DIET dry ice expanded tobacco
• tobacco material After harvesting, tobacco material can be cured to prepare the leaf for consumption.
• the tobacco material may be further treated, for example by aging or fermentation, to enhance the organoleptic properties of the tobacco.
• these processes can be lengthy and the quality of the resulting tobacco material can be variable.
• Treatments to enhance or add flavours and aromas to the tobacco material at a later stage of tobacco processing often involve the addition of one or more additive(s) to the tobacco and can require additional processing steps and equipment, which can be costly and time-consuming.
• a process for producing expanded botanical material, the process comprising: dry ice expansion of a treated botanical material, wherein the treated botanical material has previously been formed by a treatment process comprising: heating a botanical material which is enclosed within a moisture-retaining material.
• the expanded botanical material may optionally be suitable for use in a non-combustible aerosol delivery system or an aerosol-free delivery system.
• a process for producing expanded botanical material for use in (or for) a non-combustible aerosol delivery system or an aerosol-free delivery system, the process comprising: dry ice expansion of a treated botanical material, wherein the treated botanical material has previously been formed by a treatment process comprising: heating a botanical material which is enclosed within a moisture-retaining material.
• the botanical material that is treated in the treatment process may be tobacco.
• the processes of the first and second aspects may comprise dry ice expansion of tobacco material which has previously been treated by the treatment process.
• the processes of the first and second aspects may comprise treating the botanical material according to the treatment process to provide the treated botanical material, and dry ice expansion of the treated botanical material (to provide the dry ice expanded botanical material). That is, the processes may comprise carrying out the treatment process to provide the treated botanical material.
• the step of heating the botanical material may comprise exposing the botanical material to an ambient processing temperature of at least about 45°C, wherein the botanical material has a packing density on a dry matter weight base of at least 200 kg/m 3 at the start of the treatment process and has a moisture content of between about 10% and 23% before and during the treatment process.
• the treatment process may produce a botanical material with desirable organoleptic properties.
• a third aspect provides expanded botanical material which is obtainable by (or obtained by) the process of the first or second aspects.
• tobacco material to be treated in the treatment process may comprise and/or consist of post-curing tobacco.
• post-curing tobacco refers to tobacco that has been cured but has not undergone any further treatment process to alter the taste and/or aroma of the tobacco material.
• the post-curing tobacco may have been blended with other styles, varieties and/or types.
• Post-curing tobacco does not comprise or consist of cut rag tobacco.
• the botanical material is enclosed within (or secured within) a moisture-retaining material, to limit moisture losses and to retain a desired level of moisture during the treatment process.
• the moisture-retaining material may be pressure-resistant.
• the treatment process may comprise allowing the botanical material to rest when enclosed within the moisture-retaining material for a rest period, before it is heated, e.g. before the botanical material is exposed to the ambient processing temperatures described herein.
• the rest period may be at least 15 days, such as at least 30 days.
• the rest period may be from 15-75 days such as 20-60 days or 30-45 days.
• the botanical material may have a packing density of at least 200 kg/m 3 (on a dry matter weight base). Additionally or alternatively, at the start of the process, the botanical material may have a packing density up to about 500 kg/m 3 (on a dry matter weight base).
• the botanical material may have a packing density of between about 200 kg/m 3 and 330 kg/m 3 , optionally between about 220 kg/m 3 and 330 kg/m 3 .
• the botanical material has a packing density of between about 260 kg/m 3 and 300 kg/m 3 , a packing density of about 200 to about 400 kg/m 3 , or a packing density of about 250 to about 300 kg/m 3 .
• the packing density of the botanical material may be up to 220 kg/m 3 , up to 230 kg/m 3 , up to 240 kg/m 3 , up to 250 kg/m 3 , up to 260 kg/m 3 , up to 270 kg/m 3 , up to 280 kg/m 3 , up to 290 kg/m 3 , up to 300 kg/m 3 , up to 310 kg/m 3 , up to 320 kg/m 3 or up to 330 kg/m 3 .
• the botanical material may be placed in a storage container after it has been enclosed or secured within a moisture-retaining material.
• the botanical material may be placed in a storage container and then enclosed or secured within a moisture-retaining material, such as by wrapping a moisture-retaining material around the storage container. Placing the enclosed or secured botanical material in a container enables the botanical material to be handled easily.
• the packing density may be calculated by dividing the weight of botanical material on a dry matter weight base placed in the storage container by the volume of the storage container.
• the volume of the storage container and/or the volume enclosed by the moisture-retaining material may be selected to achieve the desired packing density for the desired amount of botanical material to be treated, and at the same time allows the treatment of the botanical material to take place at a suitable rate.
• the container may be oriented on its side. This arrangement may be particularly beneficial when the botanical material comprises tobacco lamina that is in a horizontal position when placed in the storage container, as placing the storage container on its side achieves a more even packing density.
• the botanical material may be placed in a processing area.
• the term 'processing area' is the area, which can be a room or chamber, in which the treatment process is carried out.
• the ambient process conditions i.e. the conditions of the processing area, may be controlled during the process. This may be achieved by placing the botanical material enclosed or secured within the moisture-retaining material into a controlled environment, such as a chamber.
• the botanical material may be placed on one or more rack(s) within a chamber, to allow optimal ventilation to maintain constant ambient process conditions around the botanical material.
• the rack(s) may have one or more shelve(s) comprising bars with gaps between the bars and/or other apertures, to assist in the maintenance of constant ambient process conditions around the botanical material.
• the ambient relative processing humidity is about 65%.
• the ambient relative processing humidity may be at least 40%, at least 45%, at least 50%, at least 55%, at least 60%, at least 65% or at least 70%.
• the ambient processing temperature is at least 46°C, at least 47°C, at least 48°C, at least 49°C, at least 50°C, at least 51°C, at least 52°C, at least 53°C, at least 54°C, at least 55°C, at least 56°C, at least 57°C, at least 58°C, at least 59°C, at least 60°C, at least 61°C, at least 62°C, at least 63°C, at least 64°C, at least 65°C, at least 66°C, at least 67°C, at least 68°C, at least 69°C or at least 70°C.
• the ambient processing temperature is up to 60°C, up to 70°C, up to 75°C, up to 80°C, up to 85°C, up to 90°C, up to 95°C, up to 100°C, up to 105°C, up to 110°C, up to 115°C or up to 120°C.
• the ambient processing humidity may be about 50-340 g water/m 3 . In embodiments in which the ambient processing temperature is about 100°C or higher, the ambient processing humidity may be about 50-500 g water/m 3 .
• the ambient processing temperature is 60°C and the ambient relative processing humidity is 60%.
• the temperature of the botanical material reaches the ambient processing temperature.
• the botanical material may reach the ambient processing temperature within a short period of time.
• the botanical material may reach the ambient processing temperature within 4 to 10 days, optionally within 5 to 9 days, within 7 to 9 days and/or within 4 to 7 days.
• the amount of botanical material treated may be optimised for the heat to be transferred to the centre of the botanical material sufficiently rapidly.
• the rate at which the temperature of the botanical material rises and reaches the ambient processing temperature will be dependent upon a number of factors, including the ambient processing temperature, the density of the botanical material and the overall amount of botanical material being treated.
• the beneficial effects of the processing according to the invention may be achieved within shorter processing periods by employing a higher ambient processing temperature.
• the temperature of the botanical material may rise during the treatment process to reach a second temperature that is higher than ambient processing temperature. This may be achieved with the assistance of exothermic reactions taking place during the treatment process.
• the botanical material reaches a second temperature which is above the ambient processing temperature.
• the second temperature is at least 1°C above the ambient processing temperature. at least 2°C, at least 3°C, at least 4°C, at least 5°C, at least 7°C, at least 10°C, at least 12°C, at least 15°C, at least 17°C or at least 20°C above the ambient processing temperature.
• the botanical material reaches a second temperature which is above the ambient processing temperature within about 7 to 13 days, and/or the second is reached within about 13 days or within about 11 days. In some embodiments, the botanical material reaches a second temperature of at least 5°C above the ambient processing temperature within about 11 to 13 days.
• the temperature of the botanical material may reach up to 60°C, up to 65°C, up to 70°C, up to 75°C, up to 80°C, up to 85°C, up to 90°C, up to 95°C, up to 100°C, up to 105°C, up to 110°C, up to 115°C, up to 120°C, up to 125°C, up to 130°C, up to 135°C, up to 140°C, up to 145°C or up to 150°C during the treatment process.
• the temperature of the botanical material may reach at least 60°C, at least 65°C, at least 70°C, at least 75°C, at least 80°C, at least 85°C, at least 90°C, at least 95°C, at least 100°C, at least 105°C, at least 110°C, at least 115°C, at least 120°C, at least 125°C, at least 130°C, at least 135°C, at least 140°C, at least 145°C or at least 150°C during the treatment process.
• the upper temperature may be limited by the thermal tolerance of the moisture-retaining material.
• the temperature of the botanical material may reach between about 55°C and about 90°C, between about 55°C and about 80°C, or between 60°C and about 70°C.
• the botanical material may be enclosed (or secured) within the moisture-retaining material for a sufficiently long period of time for the botanical to develop the desirable organoleptic properties, and for a sufficiently short period of time to not cause unwanted delay in the supply chain of the botanical material.
• the botanical material may be heated within the moisture-retaining material for a period of time and at an ambient processing temperature and ambient processing humidity suitable to give rise to an increase in the temperature of the botanical material to or above a threshold temperature, wherein the moisture content of the botanical material is between about 10% and 23%.
• the threshold temperature is 55°C, 60°C or 65°C.
• the botanical material is heated during the treatment process for between about 5 and 65 days, for between about 8 and 40 days, for between about 10 and 40 days, between about 15 and 40 days, between about 20 and 40 days, between about 25 and 35 days and/or between about 28 and 32 days.
• the botanical material is heated by exposing the botanical material to the ambient processing temperature of at least about 45°C (or any of the ambient processing temperatures disclosed herein)
• the botanical material may be exposed to the ambient processing temperature for between about 5 and 65 days, for between about 8 and 40 days, for between about 10 and 40 days, between about 15 and 40 days, between about 20 and 40 days, between about 25 and 35 days and/or between about 28 and 32 days.
• the duration of the treatment (excluding any period where the botanical material is enclosed or secured within the moisture-retaining material before being heated, such as by being exposed to the ambient processing temperature) may be between about 5 and 65 days, for between about 8 and 40 days, for between about 10 and 40 days, between about 15 and 40 days, between about 20 and 40 days, between about 25 and 35 days and/or between about 28 and 32 days.
• the botanical material is heated for (or exposed to the ambient processing temperature for) for about 30 to 65 days, such as about 40 to 50 days, or about 43 to 48 days.
• the duration of the treatment (excluding any period where the botanical material is enclosed or secured within the moisture-retaining material before being heated, such as by being exposed to the ambient processing temperature) may be about 30 to 65 days, such as about 40 to 50 days, or about 43 to 48 days.
• Increasing the duration of the treatment may increase the quantity of products of the Maillard reaction and may thereby provide a more intense flavour profile of the treated botanical material.
• the botanical may be heated under suitable conditions (for example by exposure to a suitable ambient processing temperature and ambient processing humidity) to give rise to an increase in the temperature of the botanical material to at least 55°C with the moisture content of the botanical material being between about 10% and 23% for between about 5 and 16 days.
• the organoleptic properties of the botanical material are enhanced by heating the botanical material whilst enclosed within the moisture-retaining material under those conditions for up to 18 days.
• the treatment period may be between about 6 and 12 days, between about 10 to 12 days, between about 8 to 16 days or between about 8 and 10 days.
• the botanical material may be heated under suitable conditions (for example by exposure to a suitable ambient processing temperature and ambient processing humidity) to give rise to an increase in the temperature of the botanical material to at least 55°C with the moisture content of the botanical material being between about 10% and 23% for between about 20 and 65 days.
• the organoleptic properties of the botanical material are transformed by treating the botanical material whilst enclosed within the moisture-retaining material under those conditions for at least 20 days.
• the treatment period may be between about 25 and 65 days, between about 20 to 40 days, between about 25 to 35 days or between about 30 and 35 days.
• the duration of the treatment is at least 4 days, at least 5 days, at least 6 days, at least 7 days, at least 8 days, at least 9 days, at least 10 days, at least 11 days, at least 12 days, at least 13 days, at least 14 days, at least 15 days, at least 16 days, at least 17 days, at least 18 days, at least 19 days, at least 20 days, at least 21 days, at least 22 days, at least 23 days, at least 24 days, at least 25 days, at least 26 days, at least 27 days, at least 28 days, at least 29 days, at least 30 days, at least 31 days, at least 32 days, at least 33 days, at least 34 days, at least 35 days, at least 36 days, at least 37 days, at least 38 days, at least 39 days, at least 40 days, at least 41 days, at least 42 days, at least 43 days, at least 44 days or at least 45 days.
• the duration of the treatment is up to 5 days, up to 6 days, up to 7 days, up to 8 days, up to 9 days, up to 10 days, up to 11 days, up to 12 days, up to 13 days, up to 14 days, up to 15 days, up to 16 days, up to 17 days, up to 18 days, up to 19 days, up to 20 days, up to 21 days, up to 22 days, up to 23 days, up to 24 days, up to 25 days, up to 26 days, up to 27 days, up to 28 days, up to 29 days, up to 30 days, up to 31 days, up to 32 days, up to 33 days, up to 34 days, up to 35 days, up to 36 days, up to 37 days, up to 38 days, up to 39 days, up to 40 days, up to 41 days, up to 42 days, up to 43 days, up to 44 days, up to 45 days, up to 46 days, up to 47 days, up to 48 days, up to 49 days, up to 50 days, up to 51 days, up to 52 days, up to 53 days
• the stabilisation period may be initiated by removing the botanical material from the processing area which is being held at an elevated temperature.
• the botanical material may be transported to a different processing area at a lower temperature, which may be about 30 °C or below (such as from about 18 °C to about 30 °C, or from about 20 °C to about 25 °C, e.g. around 22 °C).
• the organoleptic properties of the botanical material is a result of a reduction in the negative properties, for example as a result of a reduction in botanical material components that have an unpleasant taste or have an irritant effect.
• Proline is an example of a component that is associated with such negative properties.
• the organoleptic properties are changed by an increase in the positive properties, for example as a result of the increase in or introduction of components that make a positive contribution to the organoleptic properties, such as components having pleasant flavours.
• the process may then involve rapidly heating the botanical material to sublime the solid carbon dioxide in the cells of the botanical material, thereby causing the botanical material to expand.
• This rapid heating may be carried out by introducing the botanical material comprising solid carbon dioxide into a gas stream having a temperature of from 250 to 400 °C, such as 300-360 °C, or about 330 °C.
• Figure 2 shows a cross section through a tobacco leaf before (top) and after (bottom) dry ice expansion.
• the scale bar (centre, bottom) of each image corresponds to a distance of 100 microns. The expansion of the tobacco material during the dry ice expansion process can be seen from a comparison of these images.
• the treated DIET material may be incorporated into an aerosol-free delivery system.
• the term "delivery system” is intended to encompass systems that deliver at least one substance to a user, and includes non-combustible aerosol provision systems that release compounds from an aerosol-generating material without combusting the aerosol-generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol-generating materials; and aerosol-free delivery systems that deliver the at least one substance to a user orally, nasally, transdermally or in another way without forming an aerosol, including but not limited to, lozenges, gums, patches, articles comprising inhalable powders, and oral products such as oral tobacco which includes snus or moist snuff, wherein the at least one substance may or may not comprise nicotine.
• a "non-combustible" aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.
• the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system.
• the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol-generating material is not a requirement.
• END electronic nicotine delivery system
• the non-combustible aerosol provision system is an aerosol-generating material heating system, also known as a heat-not-burn system.
• a heat-not-burn system is a tobacco heating system.
• the non-combustible aerosol provision system may comprise a non-combustible aerosol provision device and a consumable for use with the non-combustible aerosol provision device.
• the non-combustible aerosol provision system such as a non-combustible aerosol provision device thereof, may comprise a power source and a controller.
• the power source may, for example, be an electric power source or an exothermic power source.
• the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source.
• the non-combustible aerosol provision system may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/or an aerosol-modifying agent.
• the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol-modifying agent.
• Aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol-generating material may, for example, be in the form of a solid, liquid or semi-solid (such as a gel).
• Treated tobacco material obtained in Example 3.1 was cut.
• the cut treated tobacco was then wetted to achieve a moisture content (OV) of around 26%.
• the tobacco material was then fed into an impregnator vessel, which was subsequently charged with carbon dioxide at a temperature of -20 °C for around 6 minutes under pressure.
• the impregnated tobacco material was fed into a sublimator and the pressure was then reduced to allow the liquid carbon dioxide to solidify.
• the impregnated tobacco material was then heated in a gas stream at a temperature of 330 °C which led to rapid volatilisation of the moisture and carbon dioxide in the tobacco material.

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Citations (6)

• 2024
  • 2024-01-16 EP EP24152224.2A patent/EP4588369A1/fr active Pending
• 2025
  • 2025-01-16 WO PCT/EP2025/051053 patent/WO2025153627A1/fr active Pending

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