HK1190577B - Smokeless tobacco packaging system and method - Google Patents

Description

Smokeless tobacco packaging system and method

Cross Reference to Related Applications

This application claims priority to U.S. provisional application serial No. 61/421950, filed on 12/10/2010, which is incorporated herein by reference.

Technical Field

The present disclosure relates to preformed smokeless tobacco product packaging systems that allow for improved product stability during packaging, shipping, and handling.

Background

Smokeless tobacco is tobacco that is placed in the mouth and does not burn. Three types of smokeless tobacco are generally considered: chewing tobacco, wet smokeless tobacco and dry snuff. Chewing tobacco is a coarsely divided tobacco leaf, which is typically packaged in large tobacco bags and used in board or cigarettes. Moist smokeless tobacco is moist, more finely divided tobacco which is provided in loose form or in the form of pouches and is usually packaged in canisters and used in scoops or in cheek pouches placed between the cheeks and the gums. Dry snuff is finely ground tobacco that is placed in the mouth or inhaled through the nose.

Disclosure of Invention

Some embodiments of a smokeless tobacco packaging system include a plurality of preformed smokeless tobacco products configured within a container to generally retain their shape during packaging, shipping, and adult tobacco consumer handling. The container includes a lid and a base defining an interior space. One or more preformed smokeless tobacco products are compressed between the lid of the container and the base of the container to impede movement of the one or more preformed smokeless tobacco products within the container. The article may be compressed between the lid and the base as a result of the shaped body expanding into the article after the container is closed. In such cases, the packaging system can reduce the likelihood of deformation or damage to the preformed smokeless tobacco products that might otherwise cause the products to shift in the container in response to bumpy movement.

In particular embodiments, each preformed smokeless tobacco product can include moist smokeless tobacco in combination with a selected binder such that the preformed tobacco portion can be handled by the consumer, but can also provide improved mouth feel and a pleasing aroma. Each smokeless tobacco product can have a substantially similar shape and can provide a substantially similar, predetermined portion of tobacco into the mouth of an adult tobacco consumer. Such a system may allow an adult tobacco consumer to accommodate a consistent portion of tobacco (e.g., a portion of each article stored in the mouth) while also experiencing the benefits of having the tactile sensation and flavor of smokeless tobacco exposed on the article (e.g., not impeded by paper or paper-like pouches). Thus, some embodiments of the preformed smokeless tobacco product enable an adult tobacco consumer to handle each individual preformed piece in the container without the tobacco portion unraveling prior to placement in the mouth of the adult tobacco consumer.

In some embodiments, a method of packaging a smokeless tobacco product includes compressing a mixture of tobacco and a binder into a plurality of shaped smokeless tobacco bodies, and depositing the plurality of shaped smokeless tobacco bodies into a base of a container while the bodies are in a compressed state. Each shaped smokeless tobacco body has a substantially similar predetermined shape and is adapted to expand to an expanded size after being compressed. The lid is applied to the base prior to each shaped smokeless tobacco body expanding to the expanded size. The shaped smokeless tobacco bodies are then expanded such that one or more preformed smokeless tobacco products are compressed between the base and lid to secure the one or more bodies in a substantially fixed position relative to the base and lid. The method may further comprise the step of sealing the lid to the base.

The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will be apparent from the description and drawings, and from the claims.

Drawings

Figure 1 is a perspective view of an embodiment of a preformed smokeless tobacco product having a predetermined shape.

Figure 2A is a schematic diagram illustrating a generally cylindrical container holding a plurality of preformed smokeless tobacco products, each having a generally similar shape. Figure 2A also illustrates how a user can grasp the preformed smokeless tobacco product from the container.

Figure 2B is a cross-sectional view of a closed container including the arrangement of preformed smokeless tobacco products shown in figure 2A.

Figure 3A is a perspective view of an arrangement of preformed smokeless tobacco products within a container according to a second embodiment.

Figure 3B is a cross-sectional view of a closed container including the arrangement of preformed smokeless tobacco products shown in figure 3A.

Figure 4 is a perspective view of an arrangement of preformed smokeless tobacco products within a container according to a third embodiment.

Figure 5 is a flow chart and schematic diagram illustrating an exemplary method of forming and packaging shaped smokeless tobacco bodies.

Like reference symbols in the various drawings indicate like elements.

Detailed Description

Referring to fig. 1 and 2A, some embodiments of the smokeless tobacco system 100 can include one or more preformed smokeless tobacco products 110 disposed in the interior space 101 of the container 102 including the base 103 and the lid 104. Some embodiments of the preformed smokeless tobacco product 110 can include smokeless tobacco 115 in combination with one or more selected binders. The smokeless tobacco 115 and one or more binders are compressed or molded into a convenient shape prior to packaging such that a predetermined portion of the smokeless tobacco 115 is retained by the shaped article 110, but is still exposed on the outer surface of the shaped article 110.

The preformed smokeless tobacco products 110 described herein can have an advantageous combination of material properties that enhance the satisfaction of tobacco and allow for improved tactile and flavor benefits. For example, the preformed smokeless tobacco product 110 retains its shape during processing, shipping, and handling by an adult tobacco consumer, thereby allowing the adult tobacco consumer to handle the individual preformed smokeless tobacco product without any loss of integrity of the product prior to use. Further, each smokeless tobacco product 110 in the container 102 of the system 100 (fig. 2A) can have a generally similar shape, and can also provide a substantially similar, predetermined portion of tobacco to the mouth of an adult tobacco consumer. Thus, the system 100 enables an adult tobacco consumer to hold a consistent portion of tobacco (e.g., each of the selected articles 110 is stored in the mouth) while also experiencing the tactile and flavor benefits of having smokeless tobacco exposed on the item (e.g., not retained within a paper-like pouch or sachet). Further, in some embodiments, the binder employed in the smokeless tobacco product 110 can enhance the release and/or duration of flavor. This unique combination of handling properties, mouthfeel, and flavor release can improve the experience of smokeless tobacco.

The smokeless tobacco product can be subjected to various vibratory forces between the time the smokeless tobacco product is packaged and the time an adult tobacco consumer opens the container to use the smokeless tobacco product. These vibratory forces, if strong enough, can damage the preformed smokeless tobacco product, causing the preformed smokeless tobacco product 110 to crack or break. These forces can be compounded if the preformed smokeless tobacco product is free to move within the container. On the other hand, too tightly packing the preformed smokeless tobacco products may prevent the adult tobacco consumer from using each preformed smokeless tobacco product 110.

Accordingly, the packaging system 100 of preformed smokeless tobacco products can include one or more preformed smokeless tobacco products 110 disposed between the base 103 and lid 104 of the container 102 and upon relaxation (expansion) of the preformed smokeless tobacco products 110, results in sufficient, but not excessive, compression of the products 110. Examples of such packaging systems are described in more detail below, for example in connection with fig. 2A-B and 3A-B. When under compression in the container 102, the one or more preformed smokeless tobacco products 110 exert a force on the inner surfaces of the lid 104 and base 103 and thereby impede movement of the one or more preformed smokeless tobacco products within the interior space 101 of the container. Accordingly, one or more preformed smokeless tobacco products 110 are compressed between the lid 104 and the base 103 in response to engagement of the lid 104 with the base 103 so as to secure the compressed tobacco products 110 in a substantially fixed position within the interior space 101. However, the amount of compression is preferably less than the amount required to plastically deform or rupture any preformed smokeless tobacco product 110.

Each preformed smokeless tobacco product 110 can be molded into a selected shape. After being released from the mold, the shaped smokeless tobacco body 110' can relax, thereby expanding in size. The amount of expansion may depend on the particular tobacco material, the particular binder, other additives, the amount of each ingredient, and the amount of pressure used during the molding operation. In some embodiments, the molded smokeless tobacco product can expand about 0.04 inches (i.e., about 1 millimeter) in each dimension. Such expansion can be used to create compression of one or more preformed smokeless tobacco products between the lid 104 and the base 103. As described below, the lid 104 of the container can be applied to the base 103 of the container before the shaped smokeless tobacco body 110' is fully relaxed and expanded. The container 102 can be sized such that it can provide a compressive force once the one or more preformed smokeless tobacco products 110 relax to an expanded size, but the lid 104 can be applied prior to relaxation to avoid any initial pressure against the shaped smokeless tobacco body 110'. Thus, the preformed smokeless tobacco products 110 can be packaged in a manner that results in compression of one or more products 110 between the lid 104 and the base 103 without plastically deforming or rupturing the preformed smokeless tobacco products 110 during the initial attachment of the lid 104 to the base 103. Thereafter, however, therein, engagement of the lid 104 with the base 103 causes the preformed smokeless tobacco product 110 to compress within the container 102 (as the preformed smokeless tobacco product 110 expands after initial packaging and pressing against the opposing walls of the container 102).

Different embodiments of the preformed smokeless tobacco product 110 can have a variety of different specific combinations of ingredients. These ingredients determine, at least in part, the material properties of the preformed smokeless tobacco product 110. The preformed smokeless tobacco products can also have a variety of predetermined shapes and sizes. For example, fig. 1 illustrates an embodiment of a preformed smokeless tobacco product 110 having a generally rectangular cuboid shape, wherein the corners are rounded in the longitudinal plane. Thus, as shown in fig. 2A, each preformed smokeless tobacco product 110 in the packaging system 100 can have a substantially similar shape. The shape may include at least one pair of opposing, generally parallel outer surfaces, and as shown in the described embodiment, may include three pairs of opposing, generally parallel outer surfaces. Other shapes are also possible. As used herein, "preformed" means that the article is formed into a selected article shape at or before packaging. However, the term "preformed" does not exclude articles that expand or deform to the altered shape after the molding and/or packaging process.

Briefly, in use, an adult tobacco consumer can remove one preformed smokeless tobacco product 110 from the interior space 101 of the container 102 and can place the selected product 110 into the mouth of the adult tobacco consumer, while the preformed smokeless tobacco product generally retains its preformed shape. In some embodiments, the arrangement of the preformed smokeless tobacco products 110 can provide an interstitial space along the sidewall of at least one preformed smokeless tobacco product to allow an adult tobacco consumer to easily grasp the preformed smokeless tobacco product 110. For example, as shown in fig. 2A, the container 102 can have a clearance space 150 sufficient to allow the consumer's fingers 612 and 614 to grasp the opposing end walls of the centrally-located preformed smokeless tobacco product 110. In particular embodiments, the interstitial spaces 150 extend at least 5 millimeters in a length direction along the opposing sidewalls of the centrally located preformed smokeless tobacco product 110. In some embodiments, at least 50% of the interior space 101 of the sealed container is empty so as to provide an adult tobacco consumer with sufficient interstitial space to easily grasp at least a first preformed smokeless tobacco product 110 and a subsequent preformed smokeless tobacco product 110 without damaging adjacent preformed smokeless tobacco products 110.

The adult tobacco consumer may then place the removed preformed smokeless tobacco product 110 within the mouth of the adult tobacco consumer. A portion of the tobacco 115 (e.g., tobacco material exposed at least along an outer surface of the article 110) is thereby placed in contact with an inner surface of an adult tobacco consumer's mouth. In some embodiments, the smokeless tobacco product 110 can retain its cohesiveness within the mouth of an adult tobacco consumer, thereby reducing the likelihood that a substantial portion of the tobacco 115 will break apart and thereby "float" in the mouth, but provide the adult tobacco consumer with a mouth feel and taste similar to loose smokeless tobacco.

I. Container structure and article arrangement

The preformed smokeless tobacco products can be arranged in a variety of different arrangements within a variety of different containers. As described above, the one or more preformed smokeless tobacco products 110 are compressed between the container lid 104 and the container base 103 to impede movement of the one or more preformed smokeless tobacco products 110 within the interior space 101 of the container. Thus, the container is sized to allow one or more preformed smokeless tobacco products 110 to be compressed between the container lid 104 and the container base 103 once the container is closed and the newly placed shaped smokeless tobacco product 110' is allowed to expand into the preformed smokeless tobacco product 110. Likewise, the articles 110 are arranged within the container 102 such that one or more of the articles 110 are compressed between the lid 104 and the base 103 upon expansion of the shaped smokeless tobacco articles 110'. Fig. 2A, 2B, 3A, 3B, and 4 illustrate exemplary packaging systems 100, 200, and 300 that include different arrangements of preformed smokeless tobacco products 110. It should be understood that the base 103 shown in fig. 2A-B has a different height than the base 203 shown in fig. 3A-B and 4, as the different bases are configured to accommodate both a multi-layer arrangement (e.g., the base 103 accommodating a two-layer article 110) and a single-layer arrangement (e.g., the base 203 accommodating a single-layer article 110). While the shape and size of the particular container and preformed smokeless tobacco product are illustrated, other shapes, sizes, and arrangements are also contemplated.

Referring to fig. 2A-2B, the base 103 and lid 104 releasably mate at the attachment flange 105 to maintain the freshness and other product qualities of the preformed smokeless tobacco product 110 contained therein. Such qualities may relate to, but are not limited to, texture, flavor, color, aroma, mouthfeel, taste, ease of use, and combinations thereof. In particular embodiments, the container 102 may have a generally cylindrical shape. A connecting edge 105 may be formed on the base 103 to provide a snap-fit engagement to the cover 104. Similarly, as shown in fig. 3A-B and 4, the second base 203 and the lid 104 are releasably joined at the connecting edge 105 to maintain the freshness and other product qualities of the preformed smokeless tobacco product 110 contained therein. In these embodiments, the container 202 may have a generally cylindrical shape. As previously described, the connecting edge 105 may be formed on the base 203 to provide a snap-fit engagement to the cover 104. In other embodiments, the container 102 may have a generally rectangular shape.

The cover 104 and the base 103 or 203 may include non-stick inner surfaces. The non-stick inner surface can prevent the compressed preformed smokeless tobacco product, or a portion thereof, from sticking to the container when the adult tobacco consumer opens the container to retrieve the preformed smokeless tobacco product. Referring to fig. 2B and 3B, the cover 104 includes a metal outer layer 142 and a non-stick inner layer 144. In some embodiments, the non-stick inner layer may comprise a fluorinated fluoropolymer, such as polytetrafluoroethylene. In some embodiments, the cover may be stamped from a bonded sheet comprising a metal layer and a non-stick layer. In some embodiments, the base 103 (or 203) may comprise a moldable plastic material, such as polyethylene or polypropylene. In some embodiments, the moldable plastic material may be ultra-high molecular weight polyethylene or ultra-high molecular weight polypropylene.

The packaging systems 100, 200, and 300 described herein can include one or more layers of the preformed smokeless tobacco product 110. Referring to fig. 2A and 2B, some embodiments of the packaging system 100 include two layers of the preformed smokeless tobacco products 110, at least one stack 120 of the two preformed smokeless tobacco products 110 being compressed between the lid 104 and the base 103 once the stacked formed smokeless tobacco products 110' have been expanded. Referring to fig. 3A and 3B, some embodiments of the packaging system 200 include a single layer of preformed smokeless tobacco products 110, at least one (centrally located) preformed smokeless tobacco product 110 being compressed between the lid 104 and the base 203. Similarly, as shown in fig. 4, a particular embodiment of the packaging system 300 includes a single layer of preformed smokeless tobacco products 110 (more in number than the system 200), at least one (centrally located) preformed smokeless tobacco product 110 being compressed between the lid 104 and the base 203. In other embodiments not shown, the packaging system can include three or more layers of preformed smokeless tobacco products 110, with at least one stack including three or more preformed smokeless tobacco products 110 being compressed between the lid 104 and the base 103. In such a case, at least the base 103 may be configured to be different heights. The compressed preformed smokeless tobacco products 110 (either in the stack 120 or separately) exert a force on the inner surfaces of the lid 104 and base 103 (or 203) when relaxed, thereby impeding the movement of these preformed smokeless tobacco products 110. Thus, the compressed preformed smokeless tobacco products 110 (either in the stack 120 or separately) are compressed between the lid 104 and the base 103 (or 203) due to the engagement of the lid 104 with the base 103 (or 203), thereby securing the compressed tobacco products 110 in a substantially fixed position within the interior space of the container 102 (or 202). Advantageously, the original positioning of the shaped smokeless tobacco bodies 110' is preserved after the smokeless tobacco products 110 expanded into pre-formed shapes are presented to both the adult tobacco consumer and the consumer when the can is opened, and the interstitial space between the bodies/products is maintained to facilitate removal of one or more of the pre-formed smokeless tobacco products 110.

In the embodiment shown in fig. 2A and 2B, the container 102 is sized to receive and hold a plurality of preformed smokeless tobacco products 110, and at least a portion of the container 102 is narrower than the fully relaxed thickness of the stack 120 of preformed smokeless tobacco products 110. Thus, at least a portion of the interior space 101 is sized to compress two or more preformed smokeless tobacco products 110 (e.g., a stack 120 of two or more preformed smokeless tobacco products 110).

In the embodiment shown in fig. 3A-B and 4, the container 202 is sized to receive and hold a single layer of the preformed smokeless tobacco product 110, and at least a portion of the container 202 is narrower than the fully relaxed thickness of the preformed smokeless tobacco product 110 alone. In some embodiments, the container has a constant interior space height such that all of the preformed smokeless tobacco products 110 are compressed between the lid and the base.

In other embodiments, the cover 104 or the base 103 (or 203) may include raised and/or recessed portions that provide different interior space heights. Referring to fig. 2A-B, some embodiments of the packaging system 100 include a base 103 having a raised central portion 130. The central portion 132 of the interior space 101 thus has a narrower width than the peripheral portion 134 of the interior space 101. Thus, the one or more preformed smokeless tobacco products 110 located in the central portion 132 are compressed between the lid 104 and the base 103. In some embodiments, the preformed smokeless tobacco product 110 located at the peripheral portion 134 is free to slide within the peripheral portion 134 relative to the cover 104 and the base 103. In another example, referring to the embodiment shown in fig. 3A-B and 4, the packaging system 200 or 300 can include a base 203 having a raised central portion 230. The central portion 232 of the interior space 201 thus has a narrower width than the peripheral portion 234 of the interior space 201. Thus, the one or more preformed smokeless tobacco products 110 located in the central portion 232 are compressed between the lid 104 and the base 203. In some embodiments, the preformed smokeless tobacco product 110 located at the peripheral portion 234 is free to slide within the peripheral portion 234 relative to the cover 104 and the base 203. More preferably, in other embodiments, the preformed smokeless tobacco product 110 located in the peripheral portion 134 or 234 is compressed between the cover 104 and the base 103 or 203 as it relaxes to impede movement of the preformed smokeless tobacco product within the peripheral portion 134 or 234. In some embodiments, the amount of compression of the preformed smokeless tobacco product in the central portion 132 or 232 is greater than the amount of compression of the preformed smokeless tobacco product in the peripheral portion 134 or 234. In other embodiments, the base 103 or 203 has a flat bottom wall, and all of the articles 110 are retained between the cover 104 and the base 103 in a similar manner when relaxed.

Referring to fig. 2A and 2B, in certain embodiments of the packaging system, the multiple layers of preformed smokeless tobacco products can be arranged such that the centrally located preformed smokeless tobacco products 110 are oriented in the same direction to create the stack 120, while the preformed smokeless tobacco products 110 at the peripheral portion 134 can be layered in an offset manner. In some embodiments, the top layer 112 is arranged such that it provides interstitial spaces 150 at opposite ends of the centrally located preformed smokeless tobacco product. In some embodiments, the interstitial space 150 is at least 5 millimeters wide. In some embodiments, the gap space 150 may be at least 10 millimeters long (e.g., the dimension perpendicular to the width of at least 5 millimeters). The interstitial space 150 can be sized so as to allow an adult tobacco consumer to easily grasp the centrally-located preformed smokeless tobacco product 110 at the opposite ends while avoiding damage to adjacently-located preformed smokeless tobacco products. In some embodiments, the interstitial space is sized to allow an average sized adult index finger 614 and thumb 612 to be inserted into the interstitial space without damaging the adjacent preformed smokeless tobacco products.

Still referring to fig. 2A and 2B, certain embodiments of the container 102 may have an inner diameter of about 2.47 inches (or about 62.7 millimeters) and an outer diameter of about 2.59 inches (or about 65.8 millimeters). The container 102 may have an outer height of about 0.91 inches (or about 23.1 millimeters), an inner height of the central portion 132 of about 0.81 inches (or about 20.7 millimeters), and an inner height of the peripheral portion 134 of about 0.86 inches (or about 21.8 millimeters). Two layers 112 and 113 of eight preformed smokeless tobacco products 110 are positioned within the container 102. The preformed smokeless tobacco products can be formed by mold cavities having a length L of about 0.75 inches (or about 19.0 millimeters), a width W of about 0.43 inches (or about 11.0 millimeters), and a thickness T of about 0.39 inches (or about 10.0 millimeters), respectively, which can produce preformed smokeless tobacco products 110 having a weight of about 2.35 grams. With respect to the dimensions of the preformed smokeless tobacco product 110, the term "length" refers to the longest dimension L of the preformed smokeless tobacco product 110, the term "thickness" refers to the shortest dimension T of the preformed smokeless tobacco product 110, and the term "width" refers to the dimension W that is generally perpendicular to the length and thickness. After each preformed smokeless tobacco product 110 exits the mold cavity, each preformed smokeless tobacco product can relax, expanding about 0.04 inches (or about 1 millimeter) in each dimension of length, height, and width. Thus, the interior space 101 can be sized such that the pre-relaxed preformed smokeless tobacco product 110 can be placed in the container 102 and the container closed without pressing the preformed smokeless tobacco product, but can also be sized such that at least the preformed smokeless tobacco product 110 in the central portion 132 relaxes to be compressed between the lid 104 and the base 103. In some embodiments, the peripherally disposed preformed smokeless tobacco product can be disposed in contact with a portion of the raised central portion 130, thereby being compressed between the raised central portion 130, the side wall 136 of the base 103, and the lid 104.

Referring to fig. 3A, 3B, and 4, in certain embodiments of the packaging systems 200 and 300, a single layer of the preformed smokeless tobacco products 110 can be arranged such that two centrally located preformed smokeless tobacco products 110 are compressed between the lid 104 and the base 203, respectively. The container 202 shown in fig. 3A, 3B, and 4, respectively, may have an inner diameter of about 2.47 inches (or about 62.7 millimeters), an outer diameter of about 2.59 inches (or about 65.8 millimeters), an outer height of about 0.64 inches (or about 16.3 millimeters), an inner height of the central portion 132 of about 0.48 inches (or about 12.2 millimeters), and an inner height of the peripheral portion 134 of about 0.58 inches (or about 14.7 millimeters). The preformed smokeless tobacco products can be formed by mold cavities having a length of about 0.75 inches (or about 19.0 millimeters), a width of about 0.43 inches (or about 11.0 millimeters), and a thickness of about 0.39 inches (or about 10.0 millimeters), respectively, which can produce preformed smokeless tobacco products having a weight of about 2.35 grams. After each preformed smokeless tobacco product exits the mold cavity, each preformed smokeless tobacco product can relax, expanding about 0.04 inches (or about 1 millimeter) in each dimension. Thus, the interior space 201 can be sized such that the pre-relaxed preformed smokeless tobacco product 110 can be placed in the container 202 and the container closed without pressing the preformed smokeless tobacco product, but can also be sized such that at least the preformed smokeless tobacco product 110 in the central portion 232 is relaxed to be compressed between the lid 104 and the base 203. Preferably, all of the articles 110 are at least partially compressed.

In the embodiment of the packaging system 200 shown in fig. 3A, the container 202 can include six preformed smokeless tobacco products 110 and can provide the interstitial space 150 for grasping opposing sides of the centrally located preformed smokeless tobacco product. In an alternative embodiment of the packaging system 300 shown in fig. 4, the container 202 can also comprise eight pieces and can be arranged to provide the interstitial space 150 for grasping opposing sides of the centrally located preformed smokeless tobacco product 110.

In certain embodiments, the packaging system 100, 200, or 300 may have at least 30% (volume) of void space within the container 102 or 202. In some embodiments, the void space within the container 102 or 202 is at least 40%. In other embodiments, the void space within the container 102 or 202 is at least 50%. For example, the packaging system 100 of fig. 2A and 2B includes about 53% void space in the container 102. The packaging system 200 of fig. 3A and 3B includes about 68% void space in the container 202. The packaging system 300 of fig. 4 includes about 57% void space in the container 202. While different arrangements of the preformed smokeless tobacco products 110 may increase the number to be contained within the container, the arrangement described herein may allow an adult tobacco consumer to easily access the smokeless tobacco products 110 within the container 102 without damaging adjacent preformed smokeless tobacco products 110.

II. Moulding and packaging

Referring now to fig. 5, some embodiments of a method of making and packaging a preformed smokeless tobacco product 110 into a container include the steps of molding 510, storing 530, closing 540, and sealing 560. The arrangement of shaped smokeless tobacco bodies 522 and 524 can be separated from the mold in a demolding step 520. Further, after the container is closed, the formed smokeless tobacco body 110' may relax during a relaxation period 550. While fig. 5 shows the relaxation period 550 occurring before the sealing step 560, it is to be understood that the relaxation period 550 may occur before the sealing step 560, concurrently with the sealing step 560, after the sealing step 560, or a combination thereof.

The molding process 510 may include mixing the tobacco 115, binder, and any flavoring agents or other additives together and shaping the mixture into a predetermined shape. As shown in FIG. 5, the forming plates 512 and 514 can be used to mold different layers of smokeless tobacco product in a desired configuration. In some embodiments, the sets of cavities can be arranged to correspond to a desired arrangement of preformed smokeless tobacco products 110 within the closed and/or sealed container 102. The mixture of tobacco and binder may be extruded into a die cavity. In some embodiments, an injection pressure of 50-300 pounds is used to deliver the mixture into a plurality of mold cavities. In some embodiments, injection pressures in the range of 130-170 pounds are used to deliver the mixture to the plurality of mold cavities. The mold cavity may be filled by using continuous or intermittent pressure. For example, a screw pump may be used to apply pressure to the mixture. In certain embodiments, the smokeless tobacco product can be molded by using a molding machine, such as a FORMAX F-19 molding machine or a FORMAX F-6 molding machine. Some industrial processing machinery, such as those sold by formmax of IL Mokena, may be used at rates up to 60 strokes per minute, each stroke producing multiple sets of shaped smokeless tobacco bodies 110'.

In some embodiments, the mold cavity has a volume sized to create a formed shaped smokeless tobacco body 110' having a mass of about 2.35 grams. The edges and corners of the mold cavity may be rounded to allow the formed body to be easily ejected from the mold. Although the arrangements for the different layers shown in fig. 5 are shown within different mold plates 512 and 514, a single mold plate may include multiple sets of different arrangements for the different layers and/or containers. Mold plates 512 and 514 can include a bottom wall defined by a back plate. After the tobacco/binder mixture is pressed (e.g., extruded) into the mold cavity, the back plate can be moved relative to the molding plate 512 or 514 to allow the shaped smokeless tobacco body 110' to pass through the molding plate 512 or 514. In some embodiments, the molding plates 512 and 514 can include cutters that horizontally slice the tobacco material into each mold cavity to produce multiple shaped smokeless tobacco bodies 110' per mold cavity in a single molding operation. The molded plate 512 or 514 may be made of a material selected from the group of plastic, metal, wood, or a combination thereof. For example, the die plate 512 or 514 may be made of stainless steel, aluminum, polypropylene, or polyethylene. In some embodiments, the molded sheet may include a non-stick coating, such as PTFE.

The tobacco may be cured and added to the mixer prior to molding. For example, the tobacco may be cut open fire flue cured tobacco having an oven volatile content of 48-50% by weight. The binder may be mixed with the tobacco. The binder may be a ticatoidlite powder. One or more flavoring agents and/or other additives may also be mixed with the binder and tobacco. For example, flavors and other additives may include, for example, mint flavors, sweeteners, and pH adjusters. Mixing can occur in any commercially available tabletop mixer or industrial mixer, for example, a HOBART40 pound mixer or a FORBERG250 pound PaddleMixer. Water can be added to the tobacco during or prior to mixing to alter the total oven volatiles content of the final smokeless tobacco product. The oven volatile content can also be modified by heating the mixture. In other placesIn the examples, commercially available smokeless tobacco products (e.g., Copenhagen)Long Cut) may be mixed with a binder (e.g., a ticalid LITE powder) to form a mixture.

The molding process can also be used to mold the formed smokeless tobacco body 110'. For example, the preformed smokeless tobacco product 110 can be molded or stamped with any type of design, including, but not limited to, a trademark, a product name, or any type of image. In addition, the mold cavity 516 can be used to apply flavor strips or other pre-formed structures to one or more surfaces of the shaped smokeless tobacco body. The outer located flavor bar may provide an initial burst of flavor to the adult tobacco consumer. For example, the flavor bar can be an edible or dissolvable film, which can be substantially transparent or translucent. The dissolvable film can readily dissipate when the smokeless tobacco product 110 is placed in the mouth of an adult tobacco consumer, thereby providing the adult tobacco consumer with the tactile sensation of tobacco 115 along the exterior of the product 110.

Once molded, the shaped smokeless tobacco bodies are ejected from the forming plate 512 or 514 and stored in the container 102. In certain embodiments, the shaped smokeless tobacco body 110' is separated from the mold by using the demolding in step 520. In some embodiments, the formed body is demolded and deposited directly into container 102 in a storage process 530. As shown in fig. 5, the two-tiered arrangement may include depositing a first tier 522 into a container and then depositing a second tier 524 directly on top of the first tier within the same container. As shown, layers 522 and 524 are deposited into the base of the container. However, in other embodiments, the layers may be stored on the lid 104 and then the base 103 applied to the lid 104 to store the shaped smokeless tobacco bodies within the container 102. In other embodiments, the formed smokeless tobacco bodies can be stored on an indexing conveyor during demolding, and arranged and stored in the container 102 in a desired configuration. The indexing conveyor may be used to eliminate bodies that do not meet quality control standards before the remaining articles are placed in the container 102. In some embodiments, a spacer (e.g., wax paper) may be used to separate adjacent layers. The formed smokeless tobacco body may be stored in the base 103 of the container before it is sufficiently relaxed.

After the molded smokeless tobacco body 110' is stored within the interior space 101 of the container 102, the lid 104 is mated with the attachment flange 105 of the container 102 in a closing process 540. The container 102 is closed before the formed smokeless tobacco body 110 is sufficiently relaxed. Thus, once the container is closed, the shaped smokeless tobacco body 110 can expand to be compressed between the lid 104 and the base 103 in the relaxation period 550. The relaxation can occur before, after, or simultaneously with the sealing process 560. In some embodiments, sufficient expansion occurs within about 24 hours. The label may be applied to the closed container system 100 (e.g., to the outer cylindrical sidewall of the container 102 and lid 104) in a sealing process 560. Shrink wrap 562 may also be applied to the closed container system 100 to seal the container. A plurality of filled, labeled, and shrink-wrapped packaging systems 100 may then be placed in boxes and shipped to retail locations.

Each preformed smokeless tobacco product 110 can experience significant vibration during transport of the container 102 to the retail location, stocking the container 102 at the retail location, and letting adult tobacco consumers purchase and carry the container 102 with them. Thus, the packaging techniques described herein are selected along with the relaxation and expansion characteristics of the preformed smokeless tobacco product such that the preformed smokeless tobacco product 110 maintains integrity until used by an adult tobacco consumer.

III, methods of use

Referring back to fig. 2A, the preformed smokeless tobacco product 110 can be used by removing the preformed smokeless tobacco product 110 from the container 102 and placing the completed preformed smokeless tobacco product in the mouth of an adult tobacco consumer. For example, an adult tobacco consumer may open the container 102 by removing the lid 104. When an adult tobacco consumer removes one of the preformed smokeless tobacco products 110 from the interior space 101 of the container 102, the adult tobacco consumer can grasp the preformed smokeless tobacco product 110 between the thumb 612 and index finger 614 and/or other finger of the adult tobacco consumer. The preformed smokeless tobacco product 110 retains its integrity when grasped with moderate pressure. As shown in fig. 2A, the arrangement of the preformed smokeless tobacco products 110 includes a gap space 150 on opposite sides of the centrally located preformed smokeless tobacco product 110 so that an adult tobacco consumer can grasp the preformed smokeless tobacco product 110 without destroying adjacent preformed smokeless tobacco products 110. It should be understood from the description herein that the preformed smokeless tobacco products 110 can be removed from the container 202 (shown in the embodiments of fig. 3A-B and 4) in a substantially similar manner.

An adult tobacco consumer can insert one or more preformed smokeless tobacco products 110 into the mouth of the adult tobacco consumer. For example, an adult tobacco consumer can place the preformed smokeless tobacco product 110 between the lips and gums (gums) of the adult tobacco consumer. Due to the material properties described herein, the article 110 maintains its integrity during the grasping and placing process. After the article 110 is inserted into the mouth, the article 110 may directly contact the inside of the adult tobacco consumer's mouth. The adult tobacco consumer can also apply pressure to the preformed smokeless tobacco product 110 in order to conform the smokeless tobacco product to the contours of the oral cavity. For example, an adult tobacco consumer can compress a preformed smokeless tobacco product between the lips and gums. Pressing the smokeless tobacco product can also loosen the tobacco, thereby maintaining the taste and mouthfeel experience of the loose smokeless tobacco. The smokeless tobacco product can maintain a certain viscosity even when the smokeless tobacco product is loose, thereby reducing instances of substantial portions of tobacco and binder separating from the remainder of the preformed smokeless tobacco product and "floating" within the mouth of an adult tobacco consumer. Moreover, however, the presence of the binder in the preformed smokeless tobacco product can also enhance the flavor experience by increasing the duration of flavor release as compared to loose smokeless tobacco.

IV, friability

In some embodiments, the material properties of the preformed smokeless tobacco products 110 described herein provide enhanced tobacco satisfaction. In particular, the material properties may improve handling, mouthfeel and flavour release. In certain embodiments, the material properties of one or more of the preformed smokeless tobacco products 110 can be defined in terms of the friability of the individual product. In addition, the package can protect the preformed smokeless tobacco product 110 from damage prior to use by an adult tobacco consumer. Thus, the properties of the package may be defined in terms of the friability of the overall package.

Friability is a measure of the ability of an object to reduce to smaller pieces when subjected to pressure or friction. The value of friability depends on the particular test used. The friability of the article can be tested alone and in combination with its packaging. As used herein, "friability of individual articles" is the weight percentage of material lost as a result of placing individual preformed smokeless tobacco articles into a friability drum and rotating 100 revolutions at 25rpm, which is equivalent to four (4) minutes of rotation. As used herein, "friability of an overall package" is the average weight percentage of material lost to the preformed smokeless tobacco product 110 within the package (e.g., container 102) due to placing the package containing a plurality of preformed smokeless tobacco products into a friability drum and rotating 100 revolutions at 25 rpm. The friability drum is a standard friability drum having a diameter of 152 mm. For example, standard friability drum meeting USP, EUR and DAB pharmacopoeia standards, such as Erweka GmbH D63159 friability tester with standard USP100Method friability drum, may be used to test the preformed smokeless tobacco product 110.

The preformed smokeless tobacco product 110 can have an individual product friability of at least 0.5% by weight to increase the likelihood of good mouth feel and flavor release. While non-friable products (e.g., products having an individual product friability of about zero) have good product integrity, non-friable products do not provide a mouth feel or flavor release similar to loose smokeless tobacco. Thus, in particular embodiments, an individual article friability of at least 0.5% by weight may allow the article to partially conform to the contour of an adult tobacco consumer's mouth (e.g., the contour between the lips and gums). A single article friability of at least 0.5% by weight may also allow different portions of tobacco within the article to contact the oral tissues of an adult tobacco consumer. In some embodiments, the preformed smokeless tobacco product 110 has an individual product friability of at least 1.0% by weight. In other embodiments, the preformed smokeless tobacco product 110 has an individual product friability of at least 1.5 weight percent. In certain embodiments, the individual article friability of each preformed smokeless tobacco article 110 can be greater than 1.7 weight percent.

In particular embodiments, the preformed smokeless tobacco products 110 can each have an individual product friability of less than 80 weight percent to increase the likelihood that each product 110 can be packaged, shipped, stocked, purchased, carried, and handled prior to use without significant unraveling or otherwise significantly deteriorating from their original shape and tobacco content. In some embodiments, the preformed smokeless tobacco product 110 has an individual product friability of less than 60 weight percent. In some embodiments, the preformed smokeless tobacco product 110 has an individual product friability of less than 40% (by weight). In other embodiments, the preformed smokeless tobacco product 110 has an individual product friability of less than 20% (by weight). The preformed smokeless tobacco product 110 can also have an individual product friability of less than 10% (by weight). In some embodiments, the individual article friability of each preformed smokeless tobacco article 110 is less than 4% (by weight). For example, the individual product friability of each preformed smokeless tobacco product 110 can be less than 2.1% (by weight).

The frangible preformed smokeless tobacco product may result in loss of material within the package prior to use by an adult tobacco consumer. However, the arrangement of the preformed smokeless tobacco products 110 within the container 102 as described herein can reduce the amount of material lost. In some embodiments, the system 100 has a friability of less than 10% (by weight) of the overall package. In some embodiments, the overall packaging of the system has a friability of less than 5% by weight. In some embodiments, the overall packaging of the system has a friability of less than 1% by weight. In some embodiments, the overall packaging of the system has a friability of less than 0.5% (by weight). The arrangement of the preformed smokeless tobacco products within the container 102 as described herein may result in an overall package having a friability that is less than the individual product friability of the preformed smokeless tobacco products within the container. While the container 102 protects the preformed smokeless tobacco products from the surface of the friability drum, loose interaction between the preformed smokeless tobacco products within the container during the container tumbling process may result in material loss of the preformed smokeless tobacco products as they collide with each other and/or the container walls. By having the one or more preformed smokeless tobacco products compressed between the lid and the base, and thereby impeding or restricting movement of the one or more preformed smokeless tobacco products, the friability of the entire package of the system can be reduced.

V, Components of the preparation

Some embodiments of the preformed smokeless tobacco product 110 include tobacco and a binder. The article 110 may optionally include one or more flavoring agents and other additives. The particular composition largely determines the material characteristics of the preformed smokeless tobacco product 110.

Tobacco

Any tobacco suitable for use in smokeless tobacco products can be used. And "tobacco" refers to a portion of a member of the genus nicotiana, such as a leaf, flower, and stem. Exemplary categories of tobacco include n.rustica, n.tobacum, n.tominosiferis, and n.sylvestris. Suitable tobaccos include fermented and unfermented tobaccos, dark sun-cured tobaccos, dark fire-cured tobaccos, burley tobaccos, flue-cured tobaccos, cigars, and products from whole leaf stem removal operations. For example, tobacco may be conditioned by heating, water-out and/or pasteurization steps as described in U.S. patent 2004/0118422 or 2005/0178398. In general, fermentation is characterized by high initial water content, heat generation, and a dry weight loss of 10-20%. See, for example, U.S. patent 4528993; 4660577, respectively; 4848373, and 5372149. In addition to altering the flavour of the tobacco leaf, the fermentation may alter either or both of the colour and texture of the tobacco leaf. Also during the fermentation process, evolved gases may be produced, oxygen may be absorbed, the pH may be changed, and the amount of water contained may be changed. See, for example, U.S. patent 2005/0178398 and technical Standard Specifications (1999, Chapter1in Tobacco, Production, Chemistry and Technology, Davis & Nielsen, eds., Blackwell Publishing, Oxford). The cured, or cured and fermented, tobacco may be further processed (e.g., cut, expanded, doped, ground, or comminuted) prior to incorporation into the preformed smokeless tobacco product. In some embodiments, the tobacco is cut tobacco having an oven volatiles content of between 48% and 50% by weight prior to mixing with the binder and optionally with the flavoring and other additives.

In some embodiments, tobacco can be prepared from tobacco leaves of a tobacco plant having less than 20 μ g DVT per square centimeter of green leaf tissue. For example, the tobacco may be selected from the group consisting of the tobacco described in U.S. patent publication No. 2008/0209586, which is incorporated herein by reference. Tobacco compositions comprising tobacco from such low DVT varieties exhibit improved flavor profiles in sensory panel evaluations when compared to tobacco or tobacco compositions that do not have reduced levels of DVT.

Adhesive agent

Binders suitable for use in the preformed smokeless tobacco products described herein include orally compatible polymers, such as cellulose fibers (e.g., carboxymethylcellulose (CMC), Hydroxypropylcellulose (HPC), Hydroxyethylcellulose (HEC), Hydroxypropylmethylcellulose (HPMC), and Methylcellulose (MC)); natural polymers (e.g., starch and modified starch, konjac, collagen, inulin, soy protein, whey protein, casein, and wheat gluten); seaweed-derived polymers (e.g., carrageenan (kappa, iota, lambda); alginates, (and propylene glycol alginate), microorganism-derived polymers (e.g., xanthan gum, dextrin, pullulan, curdlan, and gellan gum), extracts (e.g., locust bean gum, guar gum, tara gum, tragacanth gum, pectins (low methoxy and amidation), agar, zein, karaya gum, gelatin, linseed, chitin, and chitosan), exudates (e.g., gum arabic (arabic) and shellac), synthetic polymers (e.g., polyvinylpyrrolidone, polyethylene oxide, and polyvinyl alcohol)).

In some embodiments, the binder is guar gum, xanthan gum, cellulose, or a combination thereof. The cellulose may be carboxymethyl cellulose (CMC). For example, guar gum, xanthan gum, CMC, and some combinations thereof are available from TIC Gums corporation and the world information network, tickum. Guar gum is sold by TIC Gums under the trade name guar. Carboxymethyl cellulose (CMC) is sold by TIC Gums under the trade name TICALOSE. Xanthan gum is sold by TIC Gums under the tradename TICAXAN. TIC Gums corporation also sells some hybrid adhesives, such as the hybrid adhesive systems sold under the tradenames ticloid and TICAFILM. In some embodiments, the ticioid LITE powder is used as a binder in a preformed smokeless tobacco product.

The binder can be present in an amount that provides the preformed smokeless tobacco product 110 with the material properties described herein. The particular amount of binder used to achieve a particular material property depends, in part, on the type of binder used. In some embodiments, the preformed smokeless tobacco product 110 includes at least 0.5 weight percent binder, which can increase the likelihood that the preformed smokeless tobacco product 110 will retain its integrity during packaging and shipping. In some embodiments, the preformed smokeless tobacco product 110 has less than 5.0% (by weight) binder. In some embodiments, the binder of each preformed smokeless tobacco product 110 is 0.5 to 2.0% by weight of the preformed smokeless tobacco product. The binder can also be present in an amount of 0.5 to 1.5 weight percent per preformed smokeless tobacco product 110.

Flavoring agents and other ingredients

In some embodiments, the preformed smokeless tobacco product 110 can optionally include one or more flavoring agents. For example, suitable flavorings include wintergreen, cherry and berry type flavorings, various liqueurs and spirits such as durian spirit, bourbon, scotch, whiskey, spearmint, peppermint, lavender, cinnamon, cardamom, osbeck, clove, kusnezoff monkshood, nutmeg, sandalwood, bergamot, geranium, honey essence, rose oil, vanilla, lemon oil, orange oil, japanese mint, cinnamon, caraway, brandy, jasmine, chamomile, menthol, ylang, sage, fennel, wine flavored with "allspice", ginger, anise, coriander, coffee, alcoholic beverages, and peppermint oil from mentha species. Mint oils useful in particular embodiments of the preformed smokeless tobacco product 110 include spearmint and peppermint.

The preformed smokeless tobacco product 110 can optionally include other additives. Other additives include fillers (e.g., starch, dicalcium phosphate, lactose, sorbitol, mannitol, and microcrystalline cellulose), soluble fibers (e.g., Fibersol from pine), calcium carbonate, dicalcium carbonate, calcium sulfate, and clay), lubricants (e.g., lecithin, stearic acid, hydrogenated vegetable oil, mineral oil, polyethylene glycol 4000-6000 (PEG), Sodium Lauryl Sulfate (SLS), glyceryl palmitostearate, sodium benzoate, sodium stearyl fumarate, talc, stearates (e.g., Mg or K), and waxes (e.g., glyceryl monostearate, propylene glycol monostearate, and ethyl acetyl monoglyceride)), plasticizers (e.g., glycerin, propylene glycol, polyethylene glycol, sorbitol, mannitol, triacetin, and 1, 3-butanediol), stabilizers (e.g., ascorbic acid, sodium stearate, and sodium stearate), and the like, Cholesterol citric acid, BHT or BHA), artificial sweeteners (e.g., sucralose, saccharin, aspartame), disintegrants (e.g., starch, sodium starch glycolate, cross-linked carboxymethylcellulose, cross-linked PVP), pH stabilizers, or other compounds (e.g., vegetable oils, surfactants, preservatives). Some compounds exhibit functional attributes that fall into more than one of these categories. For example, propylene glycol may be used as a plasticizer and lubricant, and sorbitol may be used as a filler and plasticizer. Water and other oven volatiles may also be added during the mixing process (discussed below) to vary the overall oven volatiles content of the formed smokeless tobacco product 110. Various salts may also be added.

The type and amount of flavoring and other additives can also affect the material properties of the preformed smokeless tobacco product. In some embodiments, the amount of flavoring and other additives in the preformed smokeless tobacco product 110 is limited to less than 10% by weight in total. In some embodiments, the amount of flavoring in the preformed smokeless tobacco product 110 is limited to less than 5% by weight in total. For example, certain flavorants can be included in the preformed smokeless tobacco product 110 in an amount of about 3% by weight or less.

In some embodiments, the combination of tobacco, flavoring, and other additives used in the preformed smokeless tobacco product 110 can be a mixture of tobacco, flavoring, and other additives that are commercially sold as smokeless tobacco. For example, the tobacco can be a smokeless tobacco sold under the trade name SKOAL (e.g., SKOAL Long Cut) that includes flavoring agents and other additives.

Oven volatiles

Some embodiments of the preformed smokeless tobacco product 110 can have an oven total volatiles content of 10 to 61 percent by weight. Oven volatiles include water and other volatile compounds, which may be part of the tobacco, binder, flavoring, and/or other additives. As used herein, "oven volatiles" were determined by calculating the percent weight loss of the sample after drying at 110 ℃ for 3.25 hours in a preheated forced air oven. The binder may absorb some of the oven volatiles during the mixing and forming processes. In some embodiments, the oven volatiles content of the preformed smokeless tobacco product 110 is 50 to 61 weight percent. For example, the oven volatiles content of each preformed smokeless tobacco product 110 can be about 57 weight percent. In other embodiments, the oven volatiles content can be between 10% and 30% by weight to provide a snuff-like preformed smokeless tobacco product.

It should be understood that although the systems, articles, compositions of matter, and methods have been described herein in connection with a number of different embodiments, the above description of the various embodiments is intended to be illustrative, but not limiting, of the scope of the systems, articles, compositions of matter, and methods. Other embodiments, advantages, and modifications are within the scope of the following claims.

Claims (49)

1. A smokeless tobacco packaging system, comprising:

a container including a lid and a base defining an interior space; and

a plurality of preformed smokeless tobacco products having a substantially similar shape and disposed in the interior space of the container, each preformed smokeless tobacco product comprising moist smokeless tobacco and a binder, the one or more preformed smokeless tobacco products being compressed between the lid and the base in response to engagement of the lid with the base and relaxation of the one or more preformed smokeless tobacco products from a compressed state to secure the one or more preformed smokeless tobacco products in a substantially fixed position within the interior space,

wherein the base includes a raised central portion that provides a different interior space height, and the one or more preformed smokeless tobacco products are compressed between the lid and the raised central portion.

2. The system of claim 1, wherein the plurality of preformed smokeless tobacco products are placed in a single layer within the container, and at least one preformed smokeless tobacco product is compressed between the lid and base to impede movement of the one or more preformed smokeless tobacco products.

3. The system of claim 2, wherein at least 6 preformed smokeless tobacco products are disposed within the interior space of the container.

4. The system of claim 3, wherein two preformed smokeless tobacco products are centrally placed in the interior space, wherein, in response to engagement of the lid with the base, the two preformed smokeless tobacco products are compressed between the lid and base, thereby impeding movement of the two preformed smokeless tobacco products and their movement relative to the lid and base, and the remainder of the preformed smokeless tobacco products being placed along the perimeter of the interior space.

5. The system of claim 4, wherein 8 preformed smokeless tobacco products are placed within the interior space of the container.

6. The system of claim 4, wherein the base includes a raised central portion and the two preformed smokeless tobacco products are compressed between the lid and the raised central portion of the base, and wherein a remainder of the preformed smokeless tobacco products are movable within the interior space relative to the lid and base about a periphery of the interior space.

7. The system of claim 4, wherein the base includes a raised central portion and the two preformed smokeless tobacco products are compressed between the lid and the raised central portion, and wherein the remainder of the preformed smokeless tobacco products are compressed between the lid, at least a peripheral portion of the raised central portion, and the side wall of the base to impede movement of the remainder of the preformed smokeless tobacco products.

8. The system of claim 1, wherein the plurality of preformed smokeless tobacco products are placed within the container in two stacked layers, and in response to engagement of the lid with the base, at least one pair of stacked preformed smokeless tobacco products is compressed between the lid and base, thereby impeding movement of the pair of stacked preformed smokeless tobacco products relative to the lid and base.

9. The system of claim 8, wherein the pair of stacked preformed smokeless tobacco products is centrally located in the interior space, wherein, in response to engagement of the lid with the base, the pair of stacked preformed smokeless tobacco products is compressed between the lid and base, thereby impeding movement of the pair of stacked preformed smokeless tobacco products relative to the lid and base.

10. The system of claim 9, wherein the interior space of the container maintains at least two pairs of stacked smokeless tobacco products centrally located in the interior space, each of the pairs being compressed between the lid and base to impede movement of two pairs of stacked preformed smokeless tobacco products.

11. The system of claim 10, wherein the base includes a raised central portion and the two pairs of stacked preformed smokeless tobacco products are compressed between the lid and the raised central portion, wherein the remainder of the preformed smokeless tobacco products are placed near the periphery of the interior space.

12. The system of claim 11, wherein the remainder of the preformed smokeless tobacco products are stacked about the periphery of the interior space, the bottom layer of preformed smokeless tobacco products disposed about the periphery of the interior space being offset from the top layer of preformed smokeless tobacco products disposed about the periphery of the interior space.

13. The system of claim 12, wherein the remainder of the preformed smokeless tobacco product is movable within the interior space relative to the lid and base about the periphery of the interior space.

14. The system of claim 12, wherein the remainder of the preformed smokeless tobacco product is compressed between the lid, at least a peripheral portion of the raised central portion, and the side wall of the base to impede movement of the remainder of the preformed smokeless tobacco product.

15. The system of claim 8, wherein at least 16 preformed smokeless tobacco products are placed within the interior space of the container.

16. The system of claim 8, wherein the container is generally cylindrical and has an inner diameter of between 50 millimeters and 80 millimeters, and the plurality of preformed smokeless tobacco products have a thickness of between 5 and 15 millimeters, a width of between 8 and 20 millimeters, and a length of between 20 and 40 millimeters, respectively.

17. The system of claim 1, wherein the plurality of preformed smokeless tobacco products are arranged such that there is a gap of at least 5 millimeters on two opposing sides of at least one preformed smokeless tobacco product, the gap being sized such that a consumer's fingers grasp and remove the at least one preformed smokeless tobacco product without damaging adjacent preformed smokeless tobacco products.

18. The system of claim 1, wherein the cover includes a non-stick inner surface facing the base when the cover is engaged with the base.

19. The system of claim 18, wherein the cover comprises a metal having a non-stick inner coating secured thereto.

20. The system of claim 19, wherein the inner coating comprises polytetrafluoroethylene.

21. The system of claim 1, wherein the system has an overall packaged friability of less than 40% by weight.

22. The system of claim 21, wherein the system has a friability of less than 10% of a monolith can by weight.

23. The system of claim 22, wherein the system has a friability of less than 1% by weight of a one-piece canister.

24. The system of claim 23, wherein each preformed smokeless tobacco product has an individual product friability of between 1% and 80% by weight.

25. The system of claim 1, wherein the average individual product friability of the plurality of preformed smokeless tobacco products is greater than the friability of the overall package of the system.

26. The system of claim 1, wherein the plurality of preformed smokeless tobacco products have tobacco exposed along one or more outer surfaces of the preformed smokeless tobacco products.

27. The system of claim 1, wherein each of the preformed smokeless tobacco products has a substantially similar shape with at least one pair of opposing, generally parallel outer surfaces.

28. The system of claim 27, wherein each of the preformed smokeless tobacco products has a substantially similar predetermined shape defined at least in part by three pairs of opposing, generally parallel outer surfaces.

29. The system of claim 1, wherein each preformed smokeless tobacco product includes a flavoring agent.

30. The system of claim 1, wherein the binder is selected from the group consisting of hydroxyl containing compounds, dextrins or dextrin derivatives, carboxymethylcellulose, methylcellulose, konjac, collagen, inulin, soy protein, whey protein, casein, wheat gluten, carrageenan, alginates, propylene glycol alginate, xanthan gum, pullulan, curdlan, gellan gum, locust bean gum, guar gum, tara gum, tragacanth gum, pectin, agar, zein, karaya gum, gelatin, linseed, chitin, chitosan, gum arabic, polyvinylpyrrolidone, polyethylene oxide, polyvinyl alcohol, and combinations thereof.

31. The system of claim 30, wherein the hydroxyl containing compound comprises hydroxypropyl cellulose, hydroxyethyl cellulose, and hydroxypropyl methyl cellulose.

32. The system of claim 1, wherein the binder comprises guar, cellulose, or xanthan.

33. The system of claim 1, wherein each preformed smokeless tobacco product comprises 0.5 wt.% binder to 5.0 wt.% binder.

34. The system of claim 1, wherein the tobacco is moist, long cut, cured, fermented tobacco.

35. The system of claim 1, wherein the tobacco comprises tobacco prepared from a plant having less than 20 μ g DVT per square centimeter of green leaf tissue.

36. The system of claim 1, wherein each preformed smokeless tobacco product includes between 50 weight percent and 61 weight percent oven volatiles.

37. A method of packaging a smokeless tobacco product:

compressing the mixture of tobacco and binder into a plurality of shaped smokeless tobacco bodies, each shaped smokeless tobacco body having a substantially similar predetermined shape, each shaped smokeless tobacco body adapted to expand to an expanded size after being compressed;

depositing a plurality of shaped smokeless tobacco bodies in a predetermined arrangement of layers into a base of a container, the plurality of shaped smokeless tobacco bodies being in a compressed state during the depositing step; and

attaching a lid to the base to close the container prior to expansion of each shaped smokeless tobacco body to the expanded size, the plurality of shaped smokeless tobacco bodies subsequently expanding within the container to become pre-formed smokeless tobacco products such that the one or more pre-formed smokeless tobacco products are compressed between the base and lid to secure the one or more pre-formed smokeless tobacco products in a substantially fixed position relative to the base and lid,

wherein the base includes a raised central portion that provides a different interior space height, and the one or more preformed smokeless tobacco products are compressed between the lid and the raised central portion.

38. The method of claim 37, wherein the mixture of tobacco and binder is compressed into a plurality of shaped smokeless tobacco bodies in a plurality of mold cavities, and the shaped smokeless tobacco bodies are adapted to expand upon being expelled from the mold cavities.

39. The method of claim 38, wherein the plurality of mold cavities are formed in a mold plate and are arranged in a configuration corresponding to an arrangement of a plurality of shaped smokeless tobacco bodies deposited in the container base.

40. The method of claim 39, wherein the plurality of mold cavities are positioned above a base, and the plurality of shaped smokeless tobacco bodies are ejected from the mold cavities and deposited directly into the base.

41. The method of claim 39, wherein the plurality of mold cavities are positioned above the lid, and the plurality of shaped smokeless tobacco herbs are discharged onto the lid and deposited into the base of the container by connecting the lid to the base.

42. The method of claim 37, further comprising sealing the container.

43. The method of claim 37, wherein the base includes a raised central portion.

44. The method of claim 37, wherein a plurality of layers of shaped smokeless tobacco bodies are deposited into the base, and at least one stack of a plurality of shaped smokeless tobacco bodies expands to become a stack of preformed smokeless tobacco products compressed between the lid and base.

45. The method of claim 37, wherein each of the shaped smokeless tobacco bodies is compressed into a shape having at least one pair of opposing, generally parallel outer surfaces.

46. The method of claim 37, wherein each preformed smokeless tobacco product comprises 0.5 wt.% binder to 5.0 wt.% binder.

47. A method according to claim 37, wherein the tobacco is shredded tobacco.

48. A smokeless tobacco packaging system, comprising:

a container including a lid and a base defining an interior space; and

a plurality of preformed smokeless tobacco products having a substantially similar shape and disposed in the interior space of the container, each preformed smokeless tobacco product comprising moist smokeless tobacco and a binder, one or more preformed smokeless tobacco products being compressed between the lid and the base in response to engagement of the lid with the base so as to secure the one or more preformed smokeless tobacco products in a substantially fixed position within the interior space,

wherein the base includes a raised central portion that provides a different interior space height, and the one or more preformed smokeless tobacco products are compressed between the lid and the raised central portion.

49. A method of packaging a smokeless tobacco product:

compressing the mixture of article components into a plurality of shaped bodies, each shaped body adapted to expand to an expanded size after being compressed;

storing a plurality of shaped bodies in a predetermined arrangement in a container, the plurality of shaped bodies being in a compressed state during the storing step; and

closing the container prior to expansion of each shaped body to the expanded size, the plurality of shaped bodies subsequently expanding within the container such that one or more shaped bodies push against opposing walls of the container to resist movement of the one or more shaped bodies within the container,

wherein the container comprises raised and/or recessed portions providing different internal space heights, and one or more of the shaped bodies are compressed between the lid of the container and the raised and/or recessed portions.