Note: Descriptions are shown in the official language in which they were submitted.
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A ,q I1 >m pTT T trt rrvo
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raai3 iaa~wav.30aa r.c.ant83 VC a S~TivAabt~ fIIJ_Gi ~I~ttC~ld.i, l~l
pdrticulai l~ui. ~m~. cxaluxively, a smokacie filler material to
be used in cigarettes.
Filler materials that are suitable for use as tobacco
substitute material have been proposed for many years.
However, relatively little investigation into the use of
material derived from fruit has been undertaken. Where fruit
has been used, the fruit is usually a minor constituent added
to provide sugar and amino acids or as a structure-former,
gee, fOr °.'.8t.'~.'1 8, L.T:~ P3teut SgeciRicati~vn I1T~ . I ~~ v~i o
.
Similarly, USg,o83, 377. utilises similar materials including
husks together with fruit concentrate and opt~.onally carob
~e.n ~ flour_ ~~z Lath srsC'~fi.~~..~a~~vnv t~Iv°. wvr n v~~,y~dn~C
combu~ltible material, i.e. the main fuel material, is selected
fr:rii~ c:li.:f:, dLr~~, k~~~r~ti, Piusks ar shel3 rt~teric~I, i.,a. 4iic
waste products of cereals or nuts.
Thi$ invention fe able to provide a $mokable .filler
material in which fruit material is the or one of the main
combu~ti hl R f»R1 marPri a1 ~a of tho ~mnk~,3~ filler ~.r.~.tsri al .
AMENDED SHEET
,,,r,,,,~ou.,~mr~mo Ltr. rax:utx~~~~ 15 Mad. '42 11:04 P,OS~t~
15-05-2002 ~ ~~~ " -~ ' GB0102563
CA 02410656 2002-11-26
. 1A
The invention is also able to 'be used with or .without
additional tobacco material, Whether cut tobacco leaf or cut
reconstituted tobacco sheet material.
Furthermore, the smokable filler material has a.ecnoking
quality that enables the product developer to select
appropriate flavours and casings in order to provide an
acceptable smoking taste arid flavour.
EmofanBSiAMENDED SHEET
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2
The smoke derived from smokable filler material according
to the invention also provides significant reduction to the
smoker of some smoke components.
The present invention provides a smokable filler material
comprising a non-combustible inorganic filler, a binder, and
as a major organic combustible fuel material, a fruit
material.
Preferably the inorganic filler material is in the range
of 30-90% by weight of the dry materials.
Smokable filler material produced by means of casting
advantageously comprises inorganic filler material in the
range of 50-800, and more preferably >60% and even more
preferably >70% by weight of the dry materials.
Alternatively, smokable filler material produced by means
of an ex.trus,ion process preferably comprises inorganic filler
material in the range of 30-70% by weight of the dry
materials. More preferably the inorganic filler material is
in the range of 35-60%, and is even more preferably in the
range 45-55% and more preferably about 50% by weight of'the
dry materials.
The binder is preferably in the range of 3-25% by weight
of the dry materials. More preferably the binder is in the
range of 5-15%, and is more preferably less then 12% or even
more preferably less than 10% by weight of dry materials.. The
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3
binder may advantageously be about 7.5o by weight of dry
materials.
The fruit material is preferably in the range of 2-50o by
weight of the dry materials. For a smokable filler material
made by a casting process the fruit material is .more
preferably in the range of 5-15% and is even more preferably
10% or more, and may advantageously be about 12.5%. For a
smokable filler material made by the extrusion process, the
fruit material is preferably in the range of 2-50o by weight
of dry materials. More preferably the fruit material is in
the range of 10-30o and is even more preferably about 20% by
weight of the dry materials.
The smokable filler material made by a casting process
may advantageously comprise l0-20% fruit, 10,o sodium alginate,
70o chalk and 10o glycerol. An acceptable filler material can
be produced using 7.5% sodium algir~ate with a consequent
increase in the fruit content.
The smokable filler material made by an extrusion process
may advantageously comprise 10-20% fruit, 20o starch, 50%
chalk, 10o hydroxypropylcellulose and 0-loo glycerol.
The non-combustible inorganic filler material is
preferably. an inorganic tiller selected. from the group
comprising silicates or alumino-silicates, such as perlite,
vermiculite, diatomaceous earth,. talc or colloidal silica; or
metal oxides, metal salts or hydroxides such as magnesium
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4
oxide, magnesium sulphate, calcium or magnesium carbonate or
alumina. Advantageously the inorganic filler is a low density
material, suitably of <5g/cm3, preferably less than 4gcm3 and
more preferably <3g/cm3. Mixtures of these fillers are also
acceptable.
The smokable filler material may also comprise an organic
filler. Advantageously the organic filler material is inert
or relatively inert when alone, i.e. will not readily maintain
burning, but in a mixture may become more combustible, i.e.
will maintain burning. Suitable organic fillers include
insoluble alginates, such as calcium or magnesium alginate,
calcium pectinate or alginic acid, as well as non-modified
cellulose, such as treated or non-treated wood pulp or alpha
cellulose, for example. Mixtures of inert organic fillers and
inorganic fillers may also be used.
The organic filler is advantageously present in the range
of 0-400. The organic filler helps to, improve the ash
characteristics of the smokable filler material. It may be
advantageous to include a combustible organic material with
naturally low nitrogen content, i.e. less than 0.250, more
advantageously less than 0.20% and even more advantageously
less than 0.1% dwb of total nitrogen.
Advantageously the binder is an organic binder, such as
an alginate, a gum, a cellulose (modified or natural), a
pectin or pectinaceous binder, or the Group I or II metal
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salts of these binders, such as sodium carboxymethylcellulose
or sodium alginate.
Much preferred binders are alginic binders which include
soluble alginates such as ammonium alginate, sodium alginate,
sodium calcium alginate, calcium ammonium alginate, potassium
alginate, triethanol-amine alginate and propylene glycol
alginate. Alginic binders provide the preferred smoking
mechanics and taste and flavour properties for the smokable
filler according to the invention.
.Cellulosic binders include, far example, cellulose
derivatives, such as sodium carboxymethylcellulose, methyl
cellulose, hydroxypropylcellulose, hydroxyethyl cellulose or
cellulose ethers. These binders are preferred for extrusion
purposes.
Other organic binders include gums such as gum arabic,
gum ghatti, gum tragacanth, Karaya, locust bean, acacia, guar,
quince seed or xanthan gum, or gels such as agar, agarose,
carrageenans, fucoidan and furcelleran. Pectins and
pectinaceous materials can also be used as binders. Starches
can also be used as organic binders. Other suitable gums can
be selected by reference to handbooks, such as Industrial
Gums, Ed. Whistler (Academic Press). Inorganic nori-combustible
binders, such as some cements,~for example, Portland cement,
may also be used.. Combinations of the above may also be used.
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If the binder is an alginate, and in particular the
monovalent alginates, it is desirable in the processing stage
to keep the pH of the slurry above 5 and below 3, i.e. in the
range 3-5, in order to improve the binding properties of the
alginate. This may be achieved by balancing the fruit and
inorganic filler content, or by neutralising the slurry by the
addition of an acidic material such as citric acid or basic
material such as sodium carbonate, for example.
The fruit material ~is suitably one or more of most
derivatives from fruit, such as either whole fruit, dried
fruit, fruit pulp, fruit concentrate, i.e. the fruit residue
arising from the manufacture of fruit juices,~fruit paste,
fruit puree, a powdered extract of the fruit or a liquid
extract of the fruit. If a liquid extract is used, the
extract is preferably not purely sugars from the fruit.
Mixtures of each class are also acceptable. Granulation of
the fruit material by, for example, mixing a fruit liquid or
syrup with the inorganic filler, drying and granulating is
also advantageous for some fruit derivatives, in terms of ease
of processing.
Preferably the fruit selected has a 1'ow sugar content,
i.e. of the order of 700 or less. It has been found to be
advantageous for high sugar containing fruits to have sugar
removed. therefrom, so that upon addition of the fruit material
the sugar content is preferably less than 20%.
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7
Advantageously the fruit material is selected from the
class comprising soft fruits, citrus fruit, berries or
processed fruit material, such as dried powders or dietary
fibre. Preferably the fruit material is selected to have a
low nitrogen content, advantageously of <1.8% dwb and more
advantageously of <2.0% dwb, and even more advantageously of
<0.6% dwb. The fruit is suitably selected from one or more of
the following: pineapple, mango, raisin, apple, banana,
apricot, lemon, peach, kiwi or grape. The first three of this
list are particularly preferred. Seeds from these materials
are not, at this stage, considered to be of value in the
present invention.
Fruit powder or concentrate may each be mixed with water
until fully dissolved. Pulp from fruit is suitably pulverised
thereby becoming finely divided, yet allowing the fibres to
remain relatively intact. Fibres may be separated from the
liquid in order to change the ratio of fibres to liquid, if
desired. If dried fruit is utilised, the fruit is preferably
boiled in water. If high sugar fruits are utilised they are
preferably boiled and percolated, for example, to remove a
proportion of the organic acids and sugars, and then blended
to produce a homogeneous mixture or paste.
The. aerosol generating source preferably comprises
aerosol forming means, such as glycerol and/or other aerosol
forming compounds illustrated in our co-pending PCT
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8
Application No. W096/07336. These include polyhydric
alcohols, propylene glycol and triethylene glycol, esters such
as triethyl citrate, triacetin or triethylene glycol diacetate
(TEGDA), or high boiling point hydrocarbons. Other suitable
aerosol forming means will be known to those skilled in the
art.
Preferably aerosol generating means is incorporated into
the filler material at a level of 0-30%. For a smokable filler
material made by a drum cast process the aerosol generating
means is more preferably in the range of 5-15%, and even more
preferably about 10% by weight of the dry materials. For a
smokable filler material made by an extrusion process the
aerosol generating means is more preferably in the range 0-10%
and even more preferably in the range 3-5% or less by weight
of dry materials. The aerosol generating means is pumped into
the barrel of the extruder. Plasticisers are also desirable.
If the plasticiser is the same as one of the list of suitable
aerosol forming materials, the plasticiser may suitably be
present at a level such that it is not the main aerosol
producer. Each of the additional components, i.e. those other
than filler, fruit and binder, are selected according to the
final material properties desired.
Other taste and flavour materials, such as coffee, cocoa,
caramel, flavours.from roots, such as ginger or licorice, for
example, tobacco dust or tobacco extracts may also be added to
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the smokable filler material at levels <100, and preferably at
levels of <5%, by weight of the dry materials.
The smokable filler material is advantageously prepared
by mixing all the powdered material (excluding the binder),
adding water, then gradually introducing the binder whilst
subjecting the mixture to high shear. Further. water is then
added to achieve the desired viscosity.
Preferably the final slurry has a viscosity between
60,000 - 400,000 centipoise and is more preferably in the
range of 150,000,- 250,000 centipoise. The final viscosity
will depend on the method of casting (drum or band), extrusion
or paper making process to be used.
The final slurry is then suitable for casting whereupon
it may then be stored, conditioned, and then shredded to
produce cut smokable filler material.
The smokable filler material may alternatively be
produced by means of extrusion, which extruded material may be
a foamed or non-foamed material. Suitable expansion medium or
foaming means are described in our co-pending PCT Application
No. G~TO 96/07336, the subject matter thereof in relation to
expansion mediums being incorporated herein by reference
thereto. Suitable expansion mediums include starch, pullulan
or other polysaccharides, including cellulose derivatives,
solid foaming agents, inorganic salts and organic acids
providing in situ gaseous agents, organic gaseous agents,
CA 02410656 2002-11-26
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inorganic gaseous agents and volatile 1'iquid foaming agents.
The expansion medium may partly replace the inorganic filler.
The expansion medium may be present in the range of 0-40o by
weight of the dry materials and preferably less.than 30o and
more preferably is about 20%. Water is most commonly the
preferred volatile expansion agent for such expansion systems.
Alternative expansion agents are well known. The smokable
filler material is advantageously prepared by mixing all the
powdered material including the binder, then pumping water and
glycerol into the barrel of the extruder. The extruded
material may be rods, strands, filaments or sheet material
which is then cut to provide filler material. ' Entwining or
twisting of the strands or filaments may be desirable to
provide air passages, if the extruded material does not allow
the drawing of air or smoke therealong. Other downstream
processing techniques may also be, used to improve pressure
drop, if required, if extruded as a rod. Various extruded
forms are described in our co-pending PCT application and
should be taken to be incorporated herein by reference
thereto.'
The smokable filler material may also comprise a burn
additive to enhance the smoking properties of the filler
material. Depending on the properties of the filler the burn
additive is either a. burn promoter or a burn retardant.
Suitable burn additives may be selected from one or more of
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11
salts of Group I or II metals such as acetates, citrates and
other burn promoters known to the skilled man. Suitable burn
retardants include magnesium hydroxide, mono-ammonium
phosphate or magnesium chloride, for example.
The smokable filler material may also comprise an ash.
improver, which is advantageously present in the filler in the
range of 0-5%. Appropriate ash improvers include one or more
of mica, perlite, clays, such as, for example, vermiculite,
kaolinites, tales, saponites, bentonites, as well as ash
improvers such as disodium hydrogen orthophosphate, sodium
carbonate or diammonium phosphate, for example.
The present invention also provides a smoking article
comprising a rod of smokable filler material, according to an
aspect of the present invention, wrapped in a wrapper.
The smokable filler material may comprise 100% of the rod
of material wrapped in a wrapper. Alternatively the smokable
filler material of the invention may be blended with cut
tobacco or tobacco containing sheet, such as a reconstituted
sheet, for example. Preferably the amount of .tobacco material
in such a blend is not more than 40o and is more preferably
<30% by weight of the final blend.
The wrapper may suitably be a paper wrapper or a
substantially non-combustible wrapper, such as that described
i.n International Patent Application,-.Publication No. WO
96/07336. The subject matter of that application as it
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12
relates to the substantially non-combustible wrapper is
incorporated herein by reference. The wrapper thereof
advantageously contains at least 65% inorganic particulate
filler material, such as those inorganic materials described
above.
A conventional cellulose pulp paper wrapper may have a
permeability in the range 2-300 CU and preferably less than
100 CU. Such a wrapper may also be a low total filler paper
such as disclosed in~our European Patent Application No. 0 404
580 and comprising less than 14% magnesium oxide or hydroxide,
for example.
In order that the invention may be easily understood and
readily carried into effect, reference will now be made to the
following Examples.
EXAMPLE 1
The general process is described below.
Initially, water, glycerol and chalk are mixed thoroughly
using a Silverson mixer until a homogeneous slurry. is
produced. The fruit powder or concentrate is separately mixed
with a small amount of water and stirred until fully
dissolved. If dried fruits are used the fruit is boiled in
tap water for 20-30 minutes, and blended in a food processor
until a homogeneous paste is produced. Percolation to remove
the organic acids and sugars may be desirable, depending on
the sugar content of the fruits.
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The fruit paste or fruit solution is added to the chalk
slurry and mixed. Depending on the alginate binder used the
control of pH is of importance, since a low pH has been found
to detrimentally effect the binding properties of sodium
alginate or ammonium alginate binder, resulting in a poorer
quality sheet material which after cutting is unable to run
satisfactorily through a cigarette maker because of its
reduced strength.
Finally, the binder is added gradually to the mix, with
more water if required. The final viscosity of the slurry
should ideally lie between 150,000 and 250,000 centipoise.
The. slurries in the following Examples were cast on a
drum caster to produce a uniform sheet. The resulting sheet
is stored. at approximately 60%RH for 24 hours prior to
shredding using a Hauni tobacco shredder or a paper-type
shredder. After the strands have been conditioned for 48
hours the material is ready to be made into cigarettes on a
cigarette maker.
EXAMPLE 2
As representative samples three classes of fruit were
used to produce smokable filler material. Pineapple
concentrate (75° BRIX) obtained from HAX Limited, London,
powdered mango extract obtained from Key Ingredients Limited,
Cheltenham and raisins (whole fruit) from Tesco Supermarket
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1
were each separately appropriately processed into cast sheet
material and cut. The proportions of each of the materials
r.
are: 7.5% fruit material, 12.50 sodium alginate binder, 700
coarse chalk inorganic filler and loo glycerol aerosol former.
Cut material of each was then fabricated into cigarettes
of 24.70mm diameter, 64mm length with a 20mm cellulose acetate
filter and~a paper wrapper of 5CU with 0.550 potassium citrate
burn additive added thereto. This cigarette construction
enabled direct comparison to a control commercial cigarette,
in this case, a King Size, full flavour, Virginia style
cigarette.
The cigarettes were smoked under standard machine smoking
conditions of 35m1 puff of 2 second duration per minute. A
statistically relevant number of cigarettes were smoked (see
Proctor, C. et a1. The Analyst, October 1988, v. 113 p1509-
1513). ~In this instance, 5 cigarettes per pad on a port and a
mean of 4 ports was taken.
The mainstream smoke deliveries are given below in Table
1, along with the achieved reduction in deliveries compared to
the control cigarette (see Table 2).
CA 02410656 2002-11-26
WO 01/95748 PCT/GBO1/02563
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CA 02410656 2002-11-26
WO 01/95748 PCT/GBO1/02563
16
TABLE 2
Achieved reductions (%)
Cigarette Dilution
Code % Reduction (W+G/TPM)
in
TPM Water NFDPM CO NHFDPM (%)
Pineapple 48 1 61 71 97 95
Mango 52 18 62 64 99 99
Raisins 55 37 60 68 89 89
238 SE555 - - - - - 22
W - Water
G - glycerol
EXAMPLE 3
Other experimental mixtures produced included the following
samples.
TABLE 3
Fuel Sodium Glycerol Chalk
(~) Alginate (~) (~)
(~)
Spray dried tomato 20 7.5 10 62.5
Vacuum dried blackcurrant 20 7.5 10 62.5
Vacuum dried pineapple (I) 20 7.5 10 62.5
Pineapple concentrate 75 Brix(II)20 7.5 ZO 62.5
Apple concentrate 75 Brix 20 7.5 l0 62.5
Strawberry concentrate 75C 20 7.5 10 62.5
Brix
Banana concentrate 68C Brix 20 7.5 10 62.5
~
Rosemary Dry Powder 20 7.5 10 62.5
Pineapple concentrate 75 7.5 12.5 10 70
Brix(III)
Vacuum dried mango 7.5 12.5 10 70,
Dry Raisins 7.5 12.5 10 70
As can be seen from all of the examples, there are quite
significant smoke delivery advantages using smokable filler
material according to the invention.
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17
The table shows, in particular, a significant dilution in
mainstream and sidestream smoke deliveries.
Furthermore, the material also performs well in a
conventional cigarette manufacturing situation, thereby not
requiring modification of existing apparatus.
A smoke low in nitrogen-derived compounds is obtained.
Surprisingly, a low dry particulate matter content of smoke is
also obtained. Despite high levels of non-combustible
inorganic filler a,substantial smoke aerosol is generated
which comprises mainly glycerol and water.
The final product also provides a product low in nitrogen
and mean ammonia nitrogen (see Table 4).
TABLE 4
Mean Total Nitrogen & Ammonia of Drumcast Sheet Materials
Sample Description Total Nitrogen Mean Ammonia Nitrogen
(~ dwb) (~ dwb)
Tobacco SE555 2.00 0.016
Pineapple I 0.06 0.00
Tomato 0.30 0.00
Blackcurrant 0.04 0.00
Strawberry 0.02 0.00
Pineapple II 0.02 0.00
Apple 0.01 0.00
Banana 0.05 0.00
Rosemary 0.18 0.00
Mango 0.07 0.00
Pineapple III 0.02 0.00
Raisins 0.09 0.00
Extracted Raisins 0.02 0.00
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Example 4
The general process for extrusion is described below.
A dry mix is made up from chalk (50%), dried fruit or powdered
fruit (20%), pregelatinised starch (20%) and hydroxypropyl
cellulose (10%). The mix is then fed into an extruder and
water and glycerol (3-5%) pumped into the extruder. The
extruder barrel is heated at points along the barrel so as to
produce temperatures at the heated extruder cones which are
typically 70, 100, 110, 120 and 130 degrees Celsius. The
pressure at the die is typically about 30 bar, and should in
any case be less than 100 bar. The screw profile of the
extruder should be such that enough energy is put into the mix
to produce a blown extrudate when the material exits the
extruder die. The extrudate formed is in the shape of a tube
or a foamed sheet. Ideally the tube is produced with a very
small diameter hole running longitudinally through the centre.
The extrudate is CarriedAaway from the extruder die by a
suitable haul-off system.
