WO2015049382A1

WO2015049382A1 - Packaged tobacco product including pasteurised tobacco

Info

Publication number: WO2015049382A1
Application number: PCT/EP2014/071268
Authority: WO
Inventors: Philipp NEISS; Stephane CONSTANTIN
Original assignee: Philip Morris Products S.A.
Priority date: 2013-10-03
Filing date: 2014-10-03
Publication date: 2015-04-09
Also published as: ES2704051T3; EP3051965B1; CA2919748A1; ZA201600389B; PT3051965T; EP3051965A1; PL3051965T3; AU2014331062A1

Abstract

A package (10) for sale to a consumer containing tobacco material for combustible smoking articles, the package comprising outer packaging (12), a sealed inner pouch (14) within the outer packaging and pasteurised tobacco material within the sealed inner pouch. The pasteurised tobacco material has a cut width of between 0.3 mm and 0.9 mm within the sealed inner pouch.

Description

PACKAGED TOBACCO PRODUCT INCLUDING PASTEURISED TOBACCO

The present invention relates to a method for the pasteurisation of fine-cut tobacco material and to a packaged tobacco product comprising pasteurised fine-cut tobacco material.

Tobacco materials for the self assembly of smoking articles typically have a relatively high moisture content compared to the tobacco material used in pre-manufactured smoking articles such as cigarettes. For example, roll-your-own tobacco products typically have a moisture content of above about 15 to 18 percent by weight and make-your-own tobacco products typically have a moisture content of above about 18 to 21 percent by weight, while the moisture content of the tobacco material in pre-manufactured cigarettes is typically less than about 14 percent by weight.

As tobacco is an organic material, it may be subject to deterioration by microorganisms, such as mould. In moderate climates, mould spores are naturally present in the environment and moist conditions favour mould growth. The deterioration of tobacco may therefore be of particular concern for tobacco products having a high moisture content. One way to reduce or prevent mould growth is through the use of preservatives. However, the use of preservatives in tobacco products may not be desirable.

It is has previously been proposed to pasteurise snuff, a moist tobacco product, by heating the snuff in a cooker to elevated temperatures over a certain period of time. The pasteurised snuff is then removed from the cooker and further processed. For example, US patent publication US-A-2008/0156338 discloses a process for the pasteurisation of snuff wherein the pasteurisation is carried out after the snuff has been packaged in a sealed container.

WO 2013/127528 describes a method for pasteurising fine-cut tobacco material for the self assembly of smoking articles, wherein the fine-cut tobacco is pasteurised within a sealed package which is preferably the retail package. In some examples given in WO 2013/127528 one or more packages may be placed in a reusable external enclosure that can protect the package or packages during pasteurisation. However, in some cases, the retail package may contain features, such as product information or branding, that could be adversely affected by the pasteurisation conditions.

It would be desirable to provide an improved method for the pasteurisation of fine-cut tobacco material and an improved way of packaging the fine-cut pasteurised tobacco. It would be particularly desirable to provide an improved way of packaging pasteurised fine cut tobacco material for the self assembly of smoking articles. According to the invention there is provided a package for sale to a consumer containing tobacco material for combustible smoking articles, the package comprising outer packaging, a sealed inner pouch within the outer packaging and pasteurised tobacco material within the sealed inner pouch, the pasteurised tobacco material comprising tobacco material for combustible smoking articles, the tobacco material having a cut width of between 0.3 mm and 0.9 mm.

The pasteurisation of the tobacco material is preferably carried out whilst the tobacco material is within the sealed inner pouch although in certain embodiments the tobacco material may be pasteurised and then subsequently sealed within the inner pouch. The sealed inner pouch is inserted into the outer packaging after pasteurisation. The inner pouch may not be visible to the consumer in the assembled packaged product and can therefore advantageously comprise any structure and material suitable to withstand the heating required for pasteurisation. The form of the inner pouch can additionally be simplified and in particular, there is no need to provide additional flaps or lids for the opening and closure of the package, as these can be provided on the outer packaging. This simplifies the pasteurisation process and additionally reduces the likelihood of moisture being retained within the pouch following the heating.

Since the outer packaging need not be subjected to the heating process during pasteurisation, it can comprise any desired structure and material. This allows the outer packaging to be better tailored to the function of marketing, shipping and handling of the package by providing a greater flexibility in the appearance of the packaged product, including the way in which the packaged product can be opened. Since the pasteurisation can take place before the inner pouch is inserted into the outer packaging, there is no risk of degradation or damage to the outer packaging as a result of heat or moisture so that the appearance of the packaged product can be retained.

The pasteurisation of the tobacco material within the inner pouch advantageously reduces the number of microorganisms within the package and thereby increases the shelf life of the packaged product. In particular, during the pasteurisation process, the mould count within the tobacco material is significantly reduced. The outer packaging provides additional protection to the inner pouch of tobacco material which further improves the shelf life of the packaged product.

Preferably, the inner pouch and the outer packaging are fixed to one another so as to retain the inner pouch in the outer packaging. This may be achieved, for example, using a suitable adhesive or other means to seal the material of the inner pouch to the inside of the outer packaging. Preferably, the inner pouch and the outer packaging are fixed to one another such that opening of the outer packaging simultaneously opens the inner pouch. The inner pouch is therefore automatically opened to provide access to the tobacco material contained inside upon opening of the outer packaging by the consumer. This arrangement provides convenient access to the tobacco material since only a single opening step is required. Furthermore, the arrangement enables the inner pouch to be integrated within the outer packaging in a discrete manner so that the visual impact of the inner pouch when the outer packaging is open is minimised. As described above, the inner pouch and the outer packaging may be fixed to each other using a suitable adhesive or other means to seal the material of the inner pouch to the inside of the outer packaging to achieved the desired opening effect.

The inner pouch may be formed of any flexible material or combination of materials that is capable of withstanding the heating process to which the pouch is subjected during pasteurisation. Furthermore, the material should have sufficient moisture barrier properties to prevent loss of moisture from the tobacco material during processing or storage and to prevent the ingress of water or steam into the inner pouch during pasteurisation. In addition, the material forming the pouch is preferably impermeable to microorganisms. The inner pouch may be formed of a single layer material, or a laminate material, for example a metal and plastic laminate.

Preferably, the inner pouch is sealed in an air tight or gas tight manner and particularly preferably, the inner pouch is hermetically sealed with the tobacco material inside. This may be achieved, for example, by heat sealing the pouch after filling.

Preferably the inner pouch comprises a resealable opening for accessing the tobacco material. For example, the inner pouch may be sealed using a resealable or non-permanent adhesive along at least one edge. The inner pouch can therefore be resealed or at least partially resealed between openings in order to retain the freshness of the tobacco material and in particular to maintain the moisture level of the tobacco material. The resealable opening further prevents the tobacco material from falling out of the package between uses.

The outer packaging may be formed of any suitable material or combination or materials including for example, paper, cardboard, plastic, metal or combinations thereof. The outer packaging may be formed of a single layer material, or a laminate material, comprising paper, cardboard, plastic or metal foil. As described above, the inner pouch is inserted into the outer packaging after the pasteurisation process and so there is no requirement for the material forming the outer packaging to be able to withstand heating or moisture. Furthermore, there is no requirement for the outer packaging to provide a hermetic seal since this is preferably provided by the inner pouch. Preferably, the outer packaging will, however, provide certain barrier properties against moisture and microorganisms to protect the inner pouch of tobacco material during storage. This will further increase the shelf life of the packaged product as well as increasing the time for which the tobacco material can be stored after opening of the inner pouch.

The outer packaging may be a rigid container, such as a hinge lid or slide and shell container of the type used to package smoking articles. Alternatively, the outer packaging may be a 'soft' pack formed of a flexible material. In one preferred embodiment, the outer packaging is a flexible outer pouch, such as those known for use in the packaging of roll- your-own tobacco.

Preferably, the outer packaging is of a form that is suitable for product sale to the consumer. Preferably, the outer packaging is provided with branding or product information. For example, the outer packaging may be printed, embossed or debossed with branding or product information, and/or may include one or more stickers or labels containing branding or product information.

Alternatively or in addition to providing a resealable opening on the inner pouch, the outer packaging may be provided with a resealable opening. The form of the resealable opening may depend upon the form and construction of the outer packaging. For example, where the outer packaging comprises an outer pouch as described in more detail below, the outer pouch may include a flap defined by one or more lines of perforation which may be closed by means of a resealable adhesive label, or a zip lock closure. Alternatively, where the outer packaging is in the form of a rigid pack, the rigid pack may be provided with a reclosable or resealable lid portion.

The package of the present invention is suitable for a wide variety of tobacco materials including one or more tobacco types. The tobacco material may be in any suitable form and may include tobacco cut from tobacco leaves, reconstituted tobacco material, or both.

Preferably, the tobacco material is a fine-cut tobacco material having a cut width of between about 0.3 mm and about 0.9 mm, more preferably between about 0.5 mm and 0.9 mm. Fine-cut tobacco material having a cut width within these preferred ranges is particularly suitable for use in the self assembly of smoking articles, for example for use as a roll-your-own or make-your-own tobacco product. The cut width is particularly advantageous for tobacco materials intended for the assembly of smoking articles by the consumer, in particular cigarettes, which require strips or strands of a certain size in order to prevent the tobacco from falling out of the open end of the cigarette. The cut width of the fine-cut tobacco material is also important to control the combustion process of the tobacco material and to ensure a suitable resistance-to-draw during consumption of a cigarette formed from the fine-cut tobacco material. Preferably, the strands of the fine-cut tobacco material have a length of between about 6 mm and about 75 mm.

The size of the strips of fine-cut tobacco material is in contrast to the form of snus tobacco, for which the tobacco is usually ground or more finely cut and does not fall within the ranges indicated above. Reducing the tobacco into this form has a significant effect on the tobacco, for example, on its cell structure or release of essential oils, compared with a more macroscopic cutting of the leaves into parallel strip of a distinctive width. Typically, the fine-cut tobacco material is unfermented or free of salt, or both and preferably the fine-cut tobacco material is not treated in the same way as a snuff or snus product. However, the fine-cut tobacco material may comprise leaf that has been fermented before cutting. In certain preferred embodiments, the fine-cut tobacco material consists only of the strips of tobacco leaf and includes little or no other additives. Preferably, the tobacco material is free from preservatives. The lack of additives such as preservatives is one of the main reasons why the pasteurisation of the tobacco material is important.

Preferably, the moisture content of the tobacco material within the inner pouch is between about 15 percent and about 22 percent by weight, more preferably between about 16 percent and about 19 percent by weight. It is desirable to provide the tobacco material within this relatively high moisture range since this makes the strands of tobacco less brittle and facilitates rolling of the tobacco material into a tobacco rod during the self assembly of a smoking article by the consumer. The desired moisture level is typically set during tobacco processing through the appropriate addition of water or the appropriate drying conditions or a combination of both addition of water and drying conditions.

The tobacco material within the inner pouch optionally includes a humectant in order to ensure that the moisture level is retained. Suitable humectants include, for example, glycol and glycerine. Preferably, the tobacco material comprises up to about 9 percent by weight of a humectant.

The tobacco material in the package preferably has a weight of between about 10 grams and about 500 grams, more preferably between about 30 grams and about 100 grams.

The package may be overwrapped, for example with a transparent wrapper, in order to provide an additional barrier layer to protect the tobacco material.

In order to produce a package according to the invention, the tobacco material is first sealed within an inner pouch and then a pasteurisation process is carried out on the tobacco material within the pouch. After pasteurisation, the inner pouch may be inserted into the assembled outer packaging, or the outer packaging may be at least partially assembled around the inner pouch. According to the invention there is also provided a method for the production of a package as described above, the method comprising the steps of providing tobacco material in an inner pouch, sealing the inner pouch, heating the tobacco material in the inner pouch such that the tobacco material is pasteurised and inserting the inner pouch containing the pasteurised tobacco material into an outer packaging.

Advantageously, the method according to the invention involves a pasteurisation process in which the tobacco material within the inner pouch is heated under certain conditions in order to reduce the mould count. Preferably, the mould count is reduced by a factor of at least about 1000 per gram of tobacco, more preferably by a factor of at least about 100,000 per gram of tobacco. As described above, the reduction of the mould count as a result of the pasteurisation of the tobacco material advantageously increases the shelf life of the packaged product. The method of the present invention finds particular application for moist tobacco products such as fine-cut tobacco material for the self assembly of smoking articles.

Preferably, after the pasteurisation, the tobacco material is substantially free of microorganisms.

The filled inner pouch is preferably hermetically sealed. The sealing step may be carried out using a heat sealing process. The inner pouch can be at least partially evacuated before pasteurisation by partially removing air or gas from the inner pouch before sealing. This may improve the heat transfer between the tobacco material and the heating medium.

Preferably, during the heating step, the tobacco material is heated to between about 55 degrees Celsius and about 120 degrees Celsius, more preferably to between about 60 degrees Celsius and about 85 degrees Celsius. In this temperature range, an efficient pasteurisation of the tobacco material within the inner pouch can be carried out and the mould count can be significantly reduced.

Preferably, the heating is carried out for between about 30 seconds and about 30 minutes, more preferably for between about 2 minutes and about 7 minutes. The heating can usually be carried out for short period of time, if the heating temperature is high. However, pasteurisation at a low temperature for a longer time may be beneficial for the quality of the tobacco and may pose fewer requirements on the heat stability of the inner pouch. The pasteurisation conditions are selected such that deterioration of the packaging is prevented while achieving adequate pasteurisation of the entire content of the inner pouch.

Preferably, the heating step is carried out by subjecting the filled inner pouch to a heating medium, such as water, steam, air or an inert gas. The heating medium may be a mixture of water micro-droplets and saturated steam. Alternatively, the heating medium may be a mixture of water, superheated steam and air. Alternatively, the heating medium may be a mixture of water, steam and air. Generally, the heating medium may be a hot liquid or a hot liquid vapour.

The amount of heat transferred to the inner pouch and the tobacco material within the pouch can be controlled, and depends in part on the heat capacity of the heating medium. In particular, it is preferable if a current is provided in the heat medium such that the heat medium passes around the inner pouch in order to prevent regions of low temperatures.

In a preferred embodiment, the tobacco material is heated by electromagnetic radiation. The wavelength and frequency of the electromagnetic radiation can be selected to transfer an appropriate amount of heat to the tobacco material. The use of electromagnetic radiation to heat the tobacco material can advantageously reduce the time necessary for the heating step.

In a particularly preferred embodiment, the tobacco material is heated by microwave or radiofrequency dielectric heating. This may be particularly beneficial where the tobacco material has a relatively high moisture content, so that the microwave or radiofrequency field will be able to quickly heat up the dielectric component of the tobacco, water. The applied electromagnetic field power is preferably controlled to achieve uniform heating and pasteurisation of the tobacco material by temperature measurement and control of electromagnetic field generator power during continuous processing of the filled inner pouches. The applied electromagnetic field power may be controlled to achieve uniform heating and pasteurisation of the tobacco by control of electromagnetic field generator power for successive microwave heating steps. Preferably, the control takes into account the product parameters of the tobacco material being treated, such as water content. Preferably, the product parameters of the tobacco material are predefined or determined by sensors. In one embodiment, the applied electromagnetic field power is controlled based on measurements of the temperature inside the closed inner pouch, to prevent the creation of hot or cold spots during pasteurisation. The electromagnetic field power may be applied in at least two heating stages, taking into account the specific product parameters, to prevent the creation of hot or cold spots during treatment.

In certain embodiments, the heating step may be carried out at a pressure above atmospheric pressure. At such pressures, the inner pouch may be compressed, so that there is less space in between the individual tobacco particles and heat conduction in the inner pouch occurs faster. In such embodiments of the method according to the invention, the heating of the tobacco material can be carried out more uniformly and more quickly. In alternative embodiments, the pasteurisation of the tobacco material is carried out at atmospheric pressure. In other embodiments, the pasteurisation of the tobacco material is carried out at a pressure below atmospheric pressure, to allow treatment with specific pasteurisation fluids, such as water, at temperatures below 100 degrees Celsius. The pressure during pasteurisation is preferably controlled depending upon the temperature of the treatment and the heating medium outside the package or pasteurisation medium inside the package used.

In particular embodiments, a cooling step may be carried out after the heating step by subjecting the inner pouch to a cooling medium, such as cold air, water or inert gas. Again, the duration of the cooling step may be adjusted depending on the heat capacity of the cooling medium. Further, a current in the cooling medium such as one generated by a pump or by a fan may be beneficial. The cooling of the tobacco material may beneficially be effected by spraying a mist of cool water onto the inner pouch. The evaporation of small water droplets in the mist improves the cooling properties.

Gaseous cooling or heating media are typically preferred over liquid heating media. While gaseous cooling or heating media have a lower heat capacity than liquid cooling media, they impose fewer restrictions on the material of the inner pouch, and do not require the inner pouch to dry after the heating or cooling step. As the inner pouch is closed, preferably in a hermetic, usually the cooling or heating media cannot interfere with the tobacco material.

In one embodiment, the tobacco material is cooled to below ambient temperature. The tobacco material can therefore easily be maintained at the lower temperature, which enables the tobacco material to be kept fresh, thus providing a longer storage and shelf life for the packaged product. After the cooling step, the package comprising the tobacco material may be distributed whilst remaining chilled, in particular transported in a chilled state. Also, chilled storage of the tobacco material after or before transportation may be applied and is beneficial regarding the shelf life.

Preferably, the temperature of the tobacco material is monitored during the heating step. This can be achieved by monitoring the temperature around the inner pouch, and estimating from this temperature the temperature of the tobacco material. The temperature of the tobacco may be measured for example by infrared sensors. The monitoring of the temperature allows the temperature during the heating step to be controlled. By implementing an analog or digital control device that controls the amount of energy provided to the closed inner pouch comprising the tobacco material, defined conditions during the pasteurisation can be achieved. In one embodiment, the temperature of the tobacco material may be measured at the start and at the end of a heating step, and the applied heating power for a subsequent heating step adjusted to achieve a uniform, desired temperature of the tobacco material.

Preferably, the temperature in the centre of the tobacco material in the inner pouch is measured at the start and at the end of a heating step, and the applied heating power for a subsequent heating step is adjusted to achieve a uniform, desired temperature of the tobacco throughout the package.

The temperature may also be controlled or monitored during the cooling step.

In some embodiments, the temperature may be changed during the pasteurisation process. In particular, the heating step may comprise several different heat levels; thus, the inner pouch containing the tobacco material is subjected to different temperatures. This can improve the efficiency of the pasteurisation.

The filled inner pouches may be passed through a layer of heating medium, such as steam, to enable a continuous pasteurisation of the tobacco material. The packages may be conveyed through a counter-flow of heating medium, such as steam. The heating medium may comprise water micro-droplets and steam.

After pasteurisation, the inner pouch is inserted into the outer packaging and the outer packaging is preferably closed or sealed shut. The inner pouch may be inserted into the partially assembled outer packaging, the remainder of the assembly of the outer packaging being carried out with the inner pouch in place. Alternatively, the outer packaging may be fully assembled and the inner pouch merely inserted into the packaging as a final step.

According to the invention there is also provided a packaged tobacco product manufactured according to the method of the invention as described above.

The present invention also provides the use of an inner pouch for pasteurisation of tobacco, wherein tobacco material is sealed within the inner pouch for pasteurisation, and the inner pouch containing the pasteurised tobacco is then inserted into an outer packaging.

The invention will be further described, by way of example, with reference to the accompanying drawing:

Figure 1 shows a package according to the invention, with the outer packaging in an open position.

The package 10 shown in Figure 1 comprises an outer pouch 12 and an inner pouch 14 containing a pasteurised tobacco material. The inner pouch 14 is provided within the outer pouch 12 and is secured in place by means of an adhesive.

The outer pouch 12 is formed of a paper material and comprises a lid flap 16 to provide access to the inner pouch 14 and the tobacco material. The inner pouch 14 is formed of a plastic film that has been hermetically heat sealed around a portion of pasteurised fine-cut tobacco material having a cut width of between 0.3 mm and 0.9 mm and a moisture content of between about 16 percent and 18 percent by weight.

The inner pouch 14 is first filled with the fine-cut tobacco material and is then heat sealed around all of the edges except the top edge, which is instead sealed using a resealable adhesive to provide a resealable opening.

In order to pasteurise the fine-cut tobacco material within the inner pouch 14, the sealed inner pouch 14 is heated such that the tobacco material reaches a temperature of 85 degrees Celsius for 5 minutes. The heating is carried out using hot air as a heating medium. During the heating step, the temperature within the tobacco material is monitored.

Following the pasteurisation process, the inner pouch 14 is inserted into the outer pouch 12 and the lid flap 16 of the outer pouch 12 is closed and sealed, preferably using a resealable adhesive.

Claims

1 . A package for sale to a consumer containing tobacco material for combustible smoking articles, the package comprising:

outer packaging;

a sealed inner pouch within the outer packaging; and

pasteurised tobacco material within the sealed inner pouch, the pasteurised tobacco material comprising tobacco material for combustible smoking articles, the tobacco material having a cut width of between 0.3 mm and 0.9 mm.

2. A package according to claim 1 wherein the outer packaging is has branding or product information.

3. A package according to claim 1 or 2 wherein the inner pouch and the outer packaging are fixed to one another so as to retain the inner pouch in the outer packaging.

4. A package according to any preceding claim wherein the inner pouch and the outer packaging are fixed to one another such that opening of the outer packaging simultaneously opens the inner pouch.

5. A package according to any preceding claim wherein at least the inner pouch comprises a resealable opening for accessing the tobacco material.

6. A package according to any preceding claim wherein the outer packaging comprises a flexible outer pouch.

7. A package according to any preceding claim, wherein the tobacco material has a moisture content between 15 percent by weight and 22 percent by weight.

8. A package according to any preceding claim wherein the tobacco material includes a humectant.

9. A package according to any preceding claim, wherein the packaged tobacco product has a weight of between about 10 g and about 500 g.

10. A method for the for the production of a package for sale to a consumer containing tobacco material for combustible smoking articles, the method comprising the steps of:

providing the tobacco material in an inner pouch;

sealing the inner pouch; heating the tobacco material in the inner pouch such that the tobacco material is pasteurised; and

inserting the inner pouch containing the pasteurised tobacco material into outer packaging.

1 1 . A method according to claim 10 wherein the step of heating the tobacco material in the inner pouch comprises heating the tobacco material to between about 55 degrees Celsius and about 120 degrees Celsius.

12. A method according to claim 10 or 1 1 wherein the step of heating the tobacco material in the inner pouch comprises heating the tobacco material for between about 30 seconds and about 30 minutes.

13. A method according to any of claims 10 to 12 further comprising, after the step of heating the tobacco material in the inner pouch, cooling the tobacco material in the inner pouch.

14. A packaged tobacco product manufactured according to the method of any of claims 8 to 13.

15. Use of an inner pouch for pasteurisation of tobacco wherein tobacco material is sealed within the inner pouch for pasteurisation, and the inner pouch containing the pasteurised tobacco is then inserted into outer packaging.