WO2025141419A1

WO2025141419A1 - Bulk fermentation method for tobacco

Info

Publication number: WO2025141419A1
Application number: PCT/IB2024/062933
Authority: WO
Inventors: David Troy Turfler; James Hall; Timothy POYNER; Amy FEHRENBACH; Jason RUNYON; Jacob LEMMON; Swanson L. DAVIS; Jeremy Barrett Mabe
Original assignee: American Snuff Co LLC
Current assignee: American Snuff Co LLC
Priority date: 2023-12-28
Filing date: 2024-12-20
Publication date: 2025-07-03
Anticipated expiration: 2026-06-28

Abstract

The disclosure provides methods and systems for processing tobacco materials using bulk fermentation. In some embodiments, the disclosed methods include placing a bulk quantity of tobacco material (130) in a mobile container (100); storing the mobile container (100) containing the tobacco material (130) in a curing enclosure to ferment the tobacco material (130); transporting the mobile container (100) from the curing enclosure to a conveyor system (200); moving the tobacco material (130) from the mobile container (100) to the conveyor system (200) such that the tobacco material (130) is conveyed along a path defined by the conveyor system (200) and returned to the mobile container (100); and transporting the mobile container (100) back to the curing enclosure to continue to ferment the tobacco material (130).

Description

BULK FERMENTATION METHOD FOR TOBACCO

FIELD OF THE INVENTION

The present disclosure relates to methods of fermenting tobacco material and systems for facilitating fermentation of tobacco materials.

BACKGROUND OF THE INVENTION

Tobacco may be enjoyed in a so-called "smokeless" form. Particularly popular smokeless tobacco or oral products are employed by inserting some form of processed tobacco or tobacco-containing formulation into the mouth of the user. Conventional formats for such oral products include moist snuff, snus, and chewing tobacco, which are typically formed almost entirely of particulate, granular, or shredded tobacco, and which are either portioned by the user or presented to the user in individual portions, such as in single-use pouches or sachets. Other traditional forms of smokeless products include compressed or agglomerated forms, such as plugs, tablets, or pellets. Alternative product formats, such as tobaccocontaining gums and mixtures of tobacco with other plant materials, are also known. See for example, the types of smokeless oral formulations, ingredients, and processing methodologies set forth in US Pat. Nos. 1,376,586 to Schwartz; 4,513,756 to Pittman et al.; 4,528,993 to Sensabaugh, Jr. et al.; 4,624,269 to Story et al.; 4,991,599 to Tibbetts; 4,987,907 to Townsend; 5,092,352 to Sprinkle, III et al.; 5,387,416 to White et al.; 6,668,839 to Williams; 6,834,654 to Williams; 6,953,040 to Atchley et al.; 7,032,601 to Atchley et al.; and 7,694,686 to Atchley et al.; US Pat. Pub. Nos. 2004/0020503 to Williams; 2005/0115580 to Quinter et al.; 2006/0191548 to Strickland et al.; 2007/0062549 to Holton, Jr. et al.; 2007/0186941 to Holton, Jr. et al.; 2007/0186942 to Strickland et al.; 2008/0029110 to Dube et al.; 2008/0029116 to Robinson et al.; 2008/0173317 to Robinson et al.; 2008/0209586 to Neilsen et al.; 2009/0065013 to Essen et al.; and 2010/0282267 to Atchley, as well as W02004/095959 to Amarp et al., each of which is incorporated herein by reference.

Through the years, various treatment methods and additives have been proposed for altering the overall character or nature of tobacco materials utilized in tobacco products. For example, additives or treatment processes have been utilized in order to alter the chemistry or sensory properties of the tobacco material, or in the case of smokable tobacco materials, to alter the chemistry or sensory properties of mainstream smoke generated by smoking articles including the tobacco material. Various types of enzymes, bacteria, and microorganisms (e.g. , fungi and yeast) have been employed in conjunction with tobacco for the purpose of altering the chemical makeup of the tobacco, e.g., by reducing the content of certain chemical compounds. See, for example, US Pat. Nos. 3,132,651 to Keifer; 3,513,857 to Silberman; 3,240,214 to Bavley; 3,636,097 to Harvey; 3,612,065 to Rosen; 3,943,945 to Rosen; 4,135,521 to Malan; 4,140,136 to Geiss et al.; 4,151,848 to Newton et al.; 4,307,733 to Teng; 4,308,877 to Mattina et al.; 4,407,307 to Gaisch; 4,476,881 to Gravely et al.; 4,556,073 to Gravely et al.; 4,557,280 to Gravely et al.; 4,566,469 to Semp et al.; 4,572,219 to Gaisch; 4,709,710 to Gaisch; 4,716,911 to Poulose; 4,887,618 to Bemasek; 4,941,484 to Clapp; 5,099,862 to White; 5,343,879 to Teague; 5,372,149 to Roth et al.; 5,601,097 to DeGranpreet; 7,549,425 to Koga et al.; 7,549,426 to Koga et al.; and 7,556,046 to Koga et al.; Int. Appl. Publ. No. WO 2000/02464 to Kierulff; and EP Appl. No. 1094724 to Kierulff, which are all incorporated herein by reference.

Traditionally, tobacco materials have been processed and fermented to provide a desirable chemical makeup and taste characteristics. Typically, tobacco materials can be subjected to fermentation within a solid state fermentation (SSF) vessel, such as a mixer, e.g., a Plow Mixer (e.g., from Littleford Day, Inc. (Florence, KY)). Within the fermentation vessel, parameters including moisture level, salinity, and temperature can beneficially be modified as desired. However, typical tobacco fermentation vessels hold relatively small quantities of tobacco material at one time and thus provide challenges in processing large quantities of tobacco at a time.

SUMMARY OF THE INVENTION

The present disclosure provides methods and systems for processing tobacco materials using bulk fermentation. In some embodiments, the disclosure provides methods and systems that include a mobile container capable of containing bulk quantities of tobacco material, a curing enclosure, and a conveyor system adapted to convey the tobacco along a path before returning to the mobile container in order to mix/redistribute the tobacco material for more consistent fermentation within the bulk tobacco material. The present disclosure provides an efficient manner for processing large quantities of tobacco material. Surprisingly, in some embodiments, it has been determined that use of the bulk fermentation process of the present disclosure can reduce N-Nitrosonomicotine (NNN) content of the processed tobacco material.

The disclosure includes, without limitations, the following embodiments.

Embodiment 1 : A method of fermenting a bulk tobacco material, the method comprising: i) placing a bulk quantity of tobacco material in a mobile container; ii) storing the mobile container containing the tobacco material in a curing enclosure to ferment the tobacco material; iii) transporting the mobile container from the curing enclosure to a conveyor system; iv) moving the tobacco material from the mobile container to the conveyor system such that the tobacco material is conveyed along a path defined by the conveyor system and returned to the mobile container; and v) transporting the mobile container back to the curing enclosure to continue to ferment the tobacco material.

Embodiment 2: The method of Embodiment 1, wherein steps iii) through v) are repeated periodically.

Embodiment 3: The method of Embodiment 1 or 2, wherein steps iii) through v) are repeated at least once per week for period of time up to twelve weeks. Embodiment 4: The method of any one of Embodiments 1 to 3, wherein steps iii) through v) are initiated when the tobacco material in the mobile container reaches a temperature of 100 °F or above.

Embodiment 5: The method of any one of Embodiments 1 to 4, wherein the mobile container comprises a moving floor to facilitate movement of the tobacco material from the mobile container to the conveyor system.

Embodiment 6: The method of Embodiment 5, wherein the moving floor comprises a rubberized conveyor belt.

Embodiment 7: The method of any one of Embodiments 1 to 6, wherein the mobile container is a wheeled trailer with side walls defining an enclosed space for housing the tobacco material, an opening at the rear of the wheeled trailer adapted for dispensing the tobacco material onto the conveyor system, and at least one additional opening overlying the enclosed space for receiving the tobacco material from the conveyor system.

Embodiment 8: The method of any one of Embodiments 1 to 7, wherein the mobile container comprises a retractable cover for covering the at least one additional opening overlying the enclosed space.

Embodiment 9: The method of any one of Embodiments 1 to 8, wherein the conveyor system comprises a plurality of conveyor belts defining the path along which the tobacco materials travels.

Embodiment 10: The method of any one of Embodiments 1 to 9, wherein the curing enclosure is maintained at a temperature of about 70 °F to about 150 °F.

Embodiment 11: The method of any one of Embodiments 1 to 10, wherein the tobacco material is fermented in the curing enclosure for a period of about 10 to about 90 days.

Embodiment 12: The method of any one of Embodiments 1 to 11, wherein the tobacco material within the mobile container is a tobacco blend comprising an air-cured tobacco, a fire-cured tobacco, or a combination thereof.

Embodiment 13: The method of any one of Embodiments 1 to 12, wherein the tobacco material placed in the mobile container is a threshed tobacco material having a water content of about 30 to about 40% by weight, based on the total weight of the tobacco material.

Embodiment 14: The method of any one of Embodiments 1 to 13, further comprising treating the tobacco as follows prior to placing the tobacco material in the mobile container:

(a) adding water to the tobacco material to raise the water content of the tobacco material to about 20% to about 25% by weight, based on the total weight of the tobacco material;

(b) storing the tobacco material for at least about 24 hours to allow the tobacco to equilibrate;

(c) threshing the tobacco to remove tobacco stem; and

(d) adding additional water to the tobacco material to raise the water content of the tobacco material to about 30 to about 40% by weight, based on the total weight of the tobacco material.

Embodiment 15: The method of any one of Embodiments 1 to 14, further comprising discharging a fermented tobacco material from the mobile container, and cutting and drying the fermented tobacco material to form a tobacco material suitable for use in an oral product. Embodiment 16: The method of Embodiment 15, wherein the fermented tobacco material is dried to a water content of about 15% to about 25% by weight, based on the total weight of the fermented tobacco material.

Embodiment 17: The method of any one of Embodiments 1 to 16, wherein the bulk quantity of tobacco material is at least 10,000 pounds of the tobacco material, such as about 30,000 to about 60,000 pounds of tobacco material.

Embodiment 18: A system for fermenting a bulk tobacco material, the system comprising: a mobile container configured to receive a tobacco material, the mobile container comprising a receiving end, a discharge end in spaced relation to the receiving end, and a moving floor capable of transporting the tobacco material from the receiving end to the discharge end; a conveyor system configured to transport the tobacco material, wherein the conveyor system is configured to receive the tobacco material from the discharge end of the mobile container via the moving floor, transport the tobacco material over a defined path, and discharge the tobacco material back into the receiving end of the mobile container; and a curing enclosure configured to receive the mobile container and designed to facilitate fermentation of the tobacco material within the mobile container.

Embodiment 19: The system of Embodiment 18, wherein the conveyor system comprises a plurality of conveyor belts defining the path along which the tobacco materials travels.

Embodiment 20: The system of Embodiment 19, wherein the plurality of conveyor belts are configured to receive the tobacco material from the discharge end of the mobile container, transport the tobacco material along the defined path, and discharge the tobacco material into the receiving end of the mobile container.

Embodiment 21: The system of any one of Embodiments 18 to 20, wherein the mobile container is a wheeled trailer with side walls defining an enclosed space for housing the tobacco material, an opening at the receiving end of the wheeled trailer adapted for dispensing the tobacco material onto the conveyor system, and at least one additional opening overlying the enclosed space for receiving the tobacco material from the conveyor system.

Embodiment 22: The system of any one of Embodiments 18 to 21, wherein the mobile container comprises a retractable cover for covering the at least one additional opening overlying the enclosed space.

Embodiment 23 : The system of any one of Embodiments 18 to 22, wherein the moving floor comprises a rubberized conveyor belt.

Embodiment 24: The system of any one of Embodiments 18 to 23, wherein the curing enclosure comprises a heater configured to heat the tobacco material contained within the mobile container to facilitate fermentation of the tobacco material.

Embodiment 25 : The system of any one of Embodiments 18 to 24, wherein the mobile container is configured to receive at least 10,000 pounds of the tobacco material, such as about 30,000 to about 60,000 pounds of tobacco material. These and other features, aspects, and advantages of the disclosure will be apparent from a reading of the following detailed description together with the accompanying drawings, which are briefly described below. The disclosure includes any combination of two, three, four, or more of the above-noted embodiments as well as combinations of any two, three, four, or more features or elements set forth in this disclosure, regardless of whether such features or elements are expressly combined in a specific embodiment description herein. This disclosure is intended to be read holistically such that any separable features or elements of the disclosure, in any of its various aspects and embodiments, should be viewed as intended to be combinable unless the context clearly dictates otherwise.

BRIEF DESCRIPTION OF THE DRAWINGS

Having thus described aspects of the disclosure in the foregoing general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale. The drawings are examples only, and should not be construed as limiting the disclosure.

Figure 1 illustrates a curing enclosure configured to receive a mobile container containing bulk tobacco material according to an example embodiment of the present disclosure; and

Figure 2 illustrates a tobacco overhaul station including a conveyor system adapted to receive tobacco material from a mobile container such that the bulk tobacco material is conveyed along a path defined by the conveyor system and returned to the mobile container according to an example embodiment of the present disclosure.

DETAILED DESCRIPTION

The present disclosure now will be described more fully hereinafter. This disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. As used in this specification and the claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.

The present disclosure generally provides methods and systems for fermenting a bulk tobacco material. As used herein, the term “bulk tobacco material” or “bulk quantity” of tobacco material generally refers to at least about 5,000 pounds (2268 kg) of a tobacco material. In some embodiments, a bulk tobacco material as defined herein may refer to at least about 7,500 pounds (3402 kg) of tobacco material, at least about 10,000 pounds (4536 kg) of tobacco material, at least about 15,000 pounds (6804 kg) of tobacco material, at least about 20,000 pounds (9072 kg) of tobacco material, at least about 25,000 pounds (11340 kg) of tobacco material, at least about 30,000 pounds (13608 kg) of tobacco material, at least about 35,000 pounds (15876 kg) of tobacco material, at least about 40,000 pounds (18144 kg) of tobacco material, at least about 45,000 pounds (20412 kg) of tobacco material, at least about 50,000 pounds (22680 kg) of tobacco material, or more. In certain embodiments, reference to bulk tobacco material refers to about 10,000 pounds (4536 kg) to about 100,000 pounds (45359 kg) of tobacco material, or about 20,000 (9072 kg) to about 60,000 pounds (27216 kg) of tobacco material, or about 30,000 (13608 kg) to about 50,000 pounds (22680 kg) of tobacco material.

The type of tobacco material comprising the bulk tobacco material is not intended to be particularly limited and may include any tobacco material, or combination of tobacco materials, as discussed further herein. For some applications, it may be desirable to combine two or more types of tobacco. Accordingly, in some embodiments, tobaccos can be combined from two or more sources (e.g., two or more pre-blending silos) in the desired ratio. Typically, different types of tobacco are separately processed and each type is conveyed to a different pre-blending silo. For example, tobacco from the pre-blending silos can, in certain embodiments, be conveyed by weigh belt from the pre-blending silos to be combined (e.g., in a blending bulker). In some embodiments, the bulk tobacco material may contain a blend of one or more specific types of tobaccos. For example, in some embodiments, the tobacco material used in the processes and systems provided herein may comprise a tobacco blend comprising an air-cured tobacco, a fire-cured tobacco, and combinations thereof. However, the type of tobacco material used in the systems and methods provided herein is not particularly limited.

For example, the tobacco material can vary in species, type, and form. Generally, the tobacco material is obtained from for a harvested plant of the Nicotiana species. The selection of the plant from the Nicotiana species (i.e., tobacco material) utilized in the products and processes of the disclosure can vary; and in particular, the types of tobacco or tobaccos may vary. Tobaccos that can be employed include flue- cured or Virginia (e.g., K326), burley, sun-cured (e.g., Indian Kumool and Oriental tobaccos, including Katerini, Prelip, Komotini, Xanthi and Yambol tobaccos), Maryland, dark, dark-fired, dark air cured (e.g., Passanda, Cubano, Jatin and Bezuki tobaccos), light air cured (e.g., North Wisconsin and Galpao tobaccos), Indian air cured, Red Russian and Rustica tobaccos, as well as various other rare or specialty tobaccos. Descriptions of various types of tobaccos, growing practices and harvesting practices are set forth in Tobacco Production, Chemistry and Technology, Davis et al. (Eds.) (1999), which is incorporated herein by reference. Various representative types of plants from the Nicotiana species are set forth in Goodspeed, The Genus Nicotiana, (Chonica Botanica) (1954); US Pat. Nos. 4,660,577 to Sensabaugh, Jr. et al.; 5,387,416 to White et al.; 7,025,066 to Lawson et al.; and 7,798,153 to Lawrence, Jr.; each of which is incorporated herein by reference. Tobacco compositions including dark air cured tobacco are set forth in US Patent No. 8,186,360 to Marshall et al., which is incorporated herein by reference. See also, types of tobacco as set forth, for example, in US Patent Appl. Pub. No. 2011/0247640 to Beeson et al., which is incorporated herein by reference.

Example Nicotiana species include N. tabacum, N. rustica, N. alata, N. arentsii, N. excelsior, N. forgetiana, N. glauca, N. glutinosa, N. gossei, N. kawakamii, N. knightiana, N. langsdorffi, N. otophora, N. setchelli, N. sylvestris, N. tomentosa, N. tomentosiformis, N. undulata, N. x sanderae, N. africana, N. amplexicaulis, N. benavidesii, N. bonariensis, N. debneyi, N. longiflora, N. maritina, N. megalosiphon, N. occidentalis, N. paniculata, N. plumbaginifolia, N. raimondii, N. rosulata, N. simulans, N. stocktonii, N. suaveolens, N. umbratica, N. velutina, N. wigandioides, N. acaulis, N. acuminata, N. attenuata, N. benthamiana, N. cavicola, N. clevelandii, N. cordifolia, N. corymbosa, N. fragrans, N. goodspeedii, N. linearis, N. miersii, N. nudicaulis, N. obtusifolia, N. occidentalis subsp. Hersperis, N. pauciflora, N. petunioides, N. quadrivalvis, N. repanda, N. rotundifolia, N. solanifolia, and N. spegazzinii. Various representative other types of plants from the Nicotiana species are set forth in Goodspeed, The Genus Nicotiana, (Chonica Botanica) (1954); US Pat. Nos. 4,660,577 to Sensabaugh, Jr. et al.; 5,387,416 to White et al., 7,025,066 to Lawson et al.; 7,798,153 to Lawrence, Jr. and 8,186,360 to Marshall et al.; each of which is incorporated herein by reference. Descriptions of various types of tobaccos, growing practices and harvesting practices are set forth in Tobacco Production, Chemistry and Technology, Davis et al. (Eds.) (1999), which is incorporated herein by reference.

Nicotiana species from which suitable tobacco materials can be obtained can be derived using genetic-modification or crossbreeding techniques (e.g., tobacco plants can be genetically engineered or crossbred to increase or decrease production of components, characteristics or attributes). See, for example, the types of genetic modifications of plants set forth in US Pat. Nos. 5,539,093 to Fitzmaurice et al.; 5,668,295 to Wahab et al.; 5,705,624 to Fitzmaurice et al.; 5,844,119 to Weigl; 6,730,832 to Dominguez et al.; 7,173,170 to Liu et al.; 7,208,659 to Colliver et al. and 7,230,160 to Benning et al.; US Patent Appl. Pub. No. 2006/0236434 to Conkling et al.; and PCT W02008/103935 to Nielsen et al. See, also, the types of tobaccos that are set forth in US Pat. Nos. 4,660,577 to Sensabaugh, Jr. et al.; 5,387,416 to White et al.; and 6,730,832 to Dominguez et al., each of which is incorporated herein by reference.

The Nicotiana species can, in some embodiments, be selected for the content of various compounds that are present therein. For example, plants can be selected on the basis that those plants produce relatively high quantities of one or more of the compounds desired to be isolated therefrom. In certain embodiments, plants of the Nicotiana species (e.g., Galpao commun tobacco) are specifically grown for their abundance of leaf surface compounds. Tobacco plants can be grown in greenhouses, growth chambers, or outdoors in fields, or grown hydroponically.

Various parts or portions of the plant of the Nicotiana species can be included within a mixture as disclosed herein. For example, virtually all of the plant (e.g. , the whole plant) can be harvested, and employed as such. Alternatively, various parts or pieces of the plant can be harvested or separated for further use after harvest. For example, the flower, leaves, stem, stalk, roots, seeds, and various combinations thereof, can be isolated for further use or treatment. In some embodiments, the tobacco material comprises tobacco leaf (lamina). The bulk tobacco materials disclosed herein can include processed tobacco parts or pieces, cured and aged tobacco in essentially natural lamina and/or stem form, extracted tobacco pulp (e.g., using water as a solvent), or a mixture of the foregoing (e.g., a mixture that combines extracted tobacco pulp with granulated cured and aged natural tobacco lamina).

In certain embodiments, the tobacco material comprises solid tobacco material selected from the group consisting of lamina and stems. In some embodiments, the tobacco material may include tobacco lamina, or a tobacco lamina and stem. Portions of the tobacco material may have processed forms, such as processed tobacco stems (e.g., cut-rolled stems, cut-rolled-expanded stems or cut-puffed stems), or volume expanded tobacco (e.g., puffed tobacco, such as dry ice expanded tobacco (DIET)). See, for example, the tobacco expansion processes set forth in US Pat. Nos. 4,340,073 to de la Burde et al.; 5,259,403 to Guy et al.; and 5,908,032 to Poindexter, et al.; and 7,556,047 to Poindexter, et al., all of which are incorporated by reference. See, also, the types of tobacco processing techniques set forth in PCT W02005/063060 to Atchley et al., which is incorporated herein by reference.

In some embodiments, it is typical for a harvested plant of the Nicotiana species to be subjected to a curing process. For example, the bulk tobacco material can include tobacco materials that have been appropriately cured and/or aged. Descriptions of various types of curing processes for various types of tobaccos are set forth in Tobacco Production, Chemistry and Technology, Davis et al. (Eds.) (1999). Examples of techniques and conditions for curing flue-cured tobacco are set forth in Nestor et al., Beitrage Tabakforsch. Int, 20, 467-475 (2003) and US Pat. No. 6,895,974 to Peele, which are incorporated herein by reference. Representative techniques and conditions for air curing tobacco are set forth in US Pat. No. 7,650,892 to Groves et al.; Roton et al., Beitrage Tabakforsch. Int, 21, 305-320 (2005) and Staaf et al., Beitrage Tabakforsch. Int., 21, 321-330 (2005), which are incorporated herein by reference. Certain types of tobaccos can be subjected to alternative types of curing processes, such as fire curing or sun curing.

The bulk tobacco material may have a so-called "blended" form. For example, the bulk tobacco material may include a mixture of parts or pieces of dark fired, air-cured, and burley tobacco (e.g., as tobacco composed of, or derived from, tobacco lamina, or a mixture of tobacco lamina and tobacco stem). A representative blend may incorporate about 10-33 parts burley tobacco, about 10-33 parts dark fired tobacco, and about 10-33 parts air-cured tobacco on a dry weight basis.

As noted herein, the present disclosure provides systems and methods that facilitate the fermentation of bulk tobacco materials. Traditionally, tobacco materials are subjected to fermentation within a solid state fermentation (SSF) vessel, such as a mixer, e.g., a Plow Mixer (e.g., from Littleford Day, Inc. (Florence, KY)). Within the fermentation vessel, parameters including moisture level, salinity, and temperature can beneficially be modified as desired. Conventional tobacco fermentation vessels hold relatively small quantities of tobacco material, e.g., on the order of about 100 to about 500 pounds (45 to 227 kg) of tobacco material at one time. However, the present disclosure provides systems and methods capable of fermenting bulk tobacco materials as defined herein, e.g., at least about 10,000 pounds (4536 kg) of tobacco material at one time. The disclosed systems and methods advantageously provide the ability to process and ferment large quantities of tobacco material at one time, which provides increased operational efficiency and potential cost savings. Further, the methods disclosed herein advantageously provide for decreased chemistry variability by processing large quantities of tobacco material in bulk rather than in multiple smaller batches as conventionally done.

One aspect of the present disclosure provides a system for fermenting a bulk tobacco material that comprises a mobile container, a curing enclosure, and a conveyor system. The mobile container is not especially limiting. Examples include wheeled trailers or other wheeled enclosures, portable containers adapted for transport using forklifts or other vehicles designed for moving containers, cargo sleds, and the like.

As shown in Figure 1, in some embodiments the system comprises a mobile container 100 (e.g., a wheeled trailer) configured to receive a bulk tobacco material and a curing enclosure 110 (e.g., an enclosure defined by a plurality of walls and configured to receive the mobile container) designed to facilitate fermentation of bulk tobacco materials while in the mobile container 100. The size and/or capacity of the mobile container may vary, but typically the mobile container is large enough to hold at least 10,000 pounds (4536 kg) of tobacco material at a time. In some embodiments, such as the embodiment depicted in FIG. 1, the mobile container 100 is a wheeled trailer adapted to receive and transport the bulk tobacco material. For example, the wheeled trailer may be a conventional tractor trailer with an enclosed bed useful for transporting various goods. In some embodiments, portions of the wheeled trailer (e.g., the side walls thereof) may be formed of stainless steel. In some embodiments, the walls of the wheeled trailer include an internal liner constructed of an inert material (e.g., a plastic material) facing the enclosed space within the trailer, such as a Polystone® lining system available from Roechling Industrial Gastonia. Other example liner materials include polyurethane or other spray-on materials, rubber materials, composite materials, and the like. An example mobile container 100 is an EagleBridge™ Belt Trailer (e.g., from Trinity Trailer Mfg., Inc.® (Boise, ID)).

In some embodiments, the curing enclosure 110 may be a warehouse or a storage shed configured to store the mobile container 100. The size and/or capacity of the curing enclosure may vary, but typically the curing enclosure is an enclosed space with walls capable of receiving and enclosing the mobile container for storage. The curing enclosure may include one or more heaters positioned within the walls thereof; however, inclusion of the one or more heaters is not necessarily required. For example, in some embodiments, the curing enclosure may be a warehouse that is designed to heat the tobacco material within the mobile container under ambient temperature conditions.

As shown in FIG. 1, in some embodiments, the mobile container 100 is a wheeled trailer with side walls 125 (e.g., including lateral opposing side walls extending along the longitudinal length of the container and a front wall) defining an enclosed space 120 for housing a bulk tobacco material 130, an opening 140 at the rear of the wheeled trailer adapted for dispensing the bulk tobacco material, and at least one additional opening 135 overlying the enclosed space for receiving the bulk tobacco material. In some embodiments, the mobile container may also include a retractable cover 150 attached thereto for covering the at least one additional opening during transport and/or storage. The type of retractable cover is not intended to be particularly limited and may be in the form of a metal cover, a canvas cover, a tarp, and the like. In some embodiments, the retractable cover may be attached to the mobile container. In other embodiments, the retractable cover may be provided as a separate component in the curing enclosure that is not directly attached to the mobile container. In some embodiments, the mobile container 100 may also include a moving floor 160 capable of transporting and/or discharging the bulk tobacco material from the mobile container. For example, in some embodiments, the moving floor 160 is a rubberized conveyor belt positioned proximate the floor of the wheeled trailer and configured to facilitate movement of the bulk tobacco material therein.

In some embodiments, the system described herein may further comprise an overhaul station 200 for processing and redistribution of the bulk tobacco material contained in the mobile container. As shown in FIG. 2, the overhaul station 200 can include an area configured to receive the mobile container 210 and a conveyor system comprising one or more conveyer belts 220 configured to transport the bulk tobacco material 230. As shown in FIG. 2, the mobile container 210 may comprise a receiving end 240 for receiving the bulk tobacco material and a discharge end 250 positioned opposite the receiving end for discharging the bulk tobacco material therefrom. As noted above, the mobile container further includes a moving floor 260 capable of transporting the bulk tobacco material from the receiving end to the discharge end to facilitate transfer of the bulk tobacco material from the mobile container 210 to the conveyor system 220.

Reference to a receiving “end” and a discharge “end” does not infer that the tobacco must be withdrawn from an end of the mobile container 210 or returned to the mobile container at an opposing end, but rather simply means that it is typical for the tobacco material to be discharged from a first portion of the mobile container and returned to a second portion of the mobile container that is in spaced relation to the first portion. For example, is some embodiments, the tobacco material is discharged from an open end of the mobile container (e.g., via movement of the tobacco toward the end of the mobile container by a moving floor of the mobile container) and returned to the mobile container at a location spaced from the open end (e.g., return of the tobacco material to the mobile container through an opening overlying the enclosed space within the mobile container at a location within the trailer spaced from the open end).

Typically, the conveyer system 220 is configured to receive the bulk tobacco material 230 from the discharge end 250 of the mobile container 210 via the moving floor 260 and discharge the bulk tobacco material 230 back into the receiving end 240 of the mobile container 210. In some embodiments, such as the embodiment depicted in FIG. 2, the conveyor system 220 comprises a plurality of conveyor belts connected to each other and configured to receive the bulk tobacco material from the discharge end of the mobile container, transport the bulk tobacco material along a defined path, and discharge the bulk tobacco material back into the receiving end of the mobile container. The type of conveyor belts forming the conveyor system are not intended to be particularly limited. For example, the conveyor system may comprise a plurality of rubberized conveyor belts, a plurality of metal conveyor belts, and the like. The number of conveyor belts is not limiting, and can be, for example, from 2 to about 10 or 3 to about 6 conveyor belts.

Without intending to be bound by theory, it is noted that the conveyor system provides certain benefits during the fermentation process. For example, transferring the tobacco to the conveyor system one or more times during the fermentation process allows for moisture redistribution within the fermented bulk tobacco material, release of certain gases from the bulk tobacco material that are generated during fermentation, and liberation of heat from the bulk tobacco material. In some embodiments, the conveyor system 220 may further include one or more collection points 270 positioned in connection with the plurality of conveyor belts and adapted to collect the tobacco material 230 and facilitate transfer of the tobacco material from one conveyer belt to another during transport along the conveyor system prior to discharge back into the mobile container 210.

The present disclosure further provides methods of fermenting a bulk tobacco material using a mobile container, a curing enclosure configured to receive the mobile container, and a conveyor system, each of which have been described herein above. In some embodiments, such methods comprise placing a bulk tobacco material as defined herein in the mobile container. Generally, the mobile container is configured to house the tobacco material and transport it to one or more locations during processing (e.g., the overhaul station, the curing enclosure, other processing locations, etc.). In some embodiments, the method further comprises transporting the mobile container to a curing enclosure configured to receive the mobile container and storing the tobacco material in the curing enclosure for a time sufficient to ferment the tobacco material within the mobile container. Transport of the mobile container 100, 210 can occur using any known means, such as through use of a semi-tractor known in the art.

In some embodiments, the tobacco material 130 is fermented in the curing enclosure 110 for a period of about 10 days to about 90 days. In some embodiments, the tobacco material is heated in the curing enclosure for a period of at least about 10 days, at least about 20 days, at least about 30 days, at least about 40 days, at least about 50 days, at least about 60 days, at least about 70 days, at least about 80 days, at least about 90 days, or more. In some embodiments, the fermentation period is determined based on desired final pH level of the fermented tobacco. For example, in some embodiments, the fermentation is allowed to proceed until the tobacco material has a pH of about 7 or below, such as about 6.0 to about 6.9 or about 6.5 to about 6.9.

During the fermentation process, the temperature of the tobacco material in the mobile container may vary based on ambient conditions and/or the amount of heat applied to the curing enclosure. In some embodiments, the curing enclosure is maintained at a temperature of about 70 °F to about 150 °F (about 21 to about 66 °C), about 90 °F to about 150 °F (about 32 to about 66 °C), about 100 °F to about 150 °F (about 38 to about 66 °C), or about 120 °F to about 150 °F (about 49 to about 66 °C). In some embodiments, the curing enclosure is maintained at a temperature of at least about 70 °F (21 °C), at least about 80 °F (27 °C), at least about 90 °F (32 °C), at least about 100 °F (38 °C), at least about 110 °F (43 °C), at least about 120 °F (49 °C), at least about 130 °F (54 °C), at least about 140 °F (60 °C), or at least about 150 °F (66 °C).

Within the mobile container, parameters including moisture level, salinity, and temperature of the tobacco material can optionally be modified. For example, in some embodiments, the moisture level of the tobacco material can be initially modified to ensure a moisture level of at least about 10%, at least about 20%, or at least about 30%, such as between about 10% to about 50%, between about 20% and about 50% or between about 30% and about 40%. In some embodiments, the salinity of the tobacco material can be initially modified to ensure a salinity of at least about 1%, such as between about 1% and about 6% on a dry weight basis. Generally, the particular parameters of the tobacco material may be modified prior to placing the bulk tobacco material in the mobile chamber, directly in the mobile container, or during the overhaul process which is described in more detail hereinbelow. In some embodiments, the tobacco material initially placed in the mobile container is a threshed tobacco material having a water content of about 30% to about 40% by weight, based on the total weight of the threshed tobacco material.

Typically, the fermentation process of the present disclosure involve heating the bulk tobacco material in the presence of water as described herein. However, if desired, the tobacco materials can be subjected to one or more additional treatments during fermentation, for example, the tobacco material may be irradiated, pasteurized, or otherwise subjected to controlled heat treatment. Example treatment processes are detailed, for example, in US Pat. No. 8,061,362 to Mua et al., which is incorporated herein by reference. In certain embodiments, tobacco materials can optionally be treated with water and an additive capable of inhibiting reaction of asparagine to form acrylamide upon heating of the tobacco material (e.g., an additive selected from the group consisting of lysine, glycine, histidine, alanine, methionine, cysteine, glutamic acid, aspartic acid, proline, phenylalanine, valine, arginine, compositions incorporating di- and trivalent cations, asparaginase, certain non-reducing saccharides, certain reducing agents, phenolic compounds, certain compounds having at least one free thiol group or functionality, oxidizing agents, oxidation catalysts, natural plant extracts (e.g., rosemary extract), and combinations thereof. See, for example, the types of treatment processes described in US Pat. Pub. Nos. 8,434,496, 8,944,072, and 8,991,403 to Chen et al., which are all incorporated herein by reference. In certain embodiments, this type of treatment is useful where the original tobacco material is subjected to heat as described previously herein.

Typically, the bulk tobacco material is transported to an overhaul station one or more times during the fermentation process for overhaul. Typically, the overhaul process comprises (i) transporting the mobile container from the curing enclosure to a conveyor system (as described herein above); (ii) moving the bulk tobacco material from the mobile container to the conveyor system such that the bulk tobacco material is conveyed along a path defined by the conveyor system and returned to the mobile container; and (iii) transporting the mobile container back to the curing enclosure to continue to ferment the bulk tobacco material. At the overhaul station, the mobile container may be connected to a conveyor system (as discussed herein above) designed to receive the bulk tobacco material from the discharge end of the mobile container via the moving floor such that the tobacco material is conveyed along a path defined by the conveyor system and returned to the mobile container. As noted herein, the conveyor system may include one or a plurality of conveyor belts that transport the tobacco material along a defined path before returning the tobacco material to the mobile container. After the mobile container is transported to the overhaul station and the tobacco material is processed using the conveyer system, the mobile container is then transported back to the curing enclosure to continue fermenting the tobacco material.

If desired, the overhaul process can further include treatment of the tobacco while the tobacco is conveyed. For example, the overhaul station could include a section with a plurality of spray nozzles for adding additional water to the tobacco if the tobacco is perceived to be drier than desirable. For example, water could be added at the overhaul station to maintain the tobacco material at a water content of about 30% to about 40% by weight, based on the total weight of the tobacco material. As noted herein, the overhaul process (e.g., steps (i)-(iii) provided above) may be conducted one or more times during the fermentation process. In some embodiments, the overhaul process is conducted periodically during the fermentation process. Reference to “periodic” or “periodically” is not intended to infer that the overhaul process is necessarily conducted at regular pre-defined intervals, but rather is intended to convey that the overhaul process is conducted from time to time as explained more fully below.

In certain embodiments, the overhaul process may be repeated at least once per week for a period of time up to about twelve weeks. In some embodiments, the overhaul process may be conducted at least once per month, at least once per week, at least twice per week, or more as desired. Typically, the overhaul process is initiated when the tobacco material in the mobile container reaches a temperature of about 100 °F (38 °C) or above. In some embodiments, the overhaul process is initiated when the tobacco material in the mobile container reaches a temperature of at least about 80 °F (27 °C), at least about 90 °F (32 °C), at least about 100 °F (38 °C), at least about 110 °F (43 °C), or at least about 120 °F (49 °C), or more, such as when the tobacco material reaches a temperature of about 90 °F to about 110 °F (about 32 to about 43 °C) or about 95 °F to about 105 °F (about 35 to about 41 °C). As noted herein, the overhaul process advantageously provides moisture redistribution throughout the bulk tobacco material, heat dissipation within the bulk tobacco material, and release of gases that can build up in the bulk tobacco material during fermentation.

In some aspects of the present disclosure, the bulk tobacco material that is placed in the mobile container may undergo one or more treatments and/or processing steps prior to being placed in the mobile container. For example, the tobacco material may undergo one or more water addition stages and/or processing stages prior to being placed in the mobile container. In certain embodiments, for example, the disclosed methods comprise treating the bulk tobacco material prior to placing the bulk tobacco material in the mobile container. Generally, the bulk tobacco is treated using a two-step water addition in combination with a threshing step as follows. First, the treatment step comprises adding water to the tobacco material to raise the water content of the tobacco material to about 20% to about 25% by weight, based on the total weight of the tobacco material. Next, the tobacco material (with water added) is stored for at least about 24 hours to allow the tobacco material to equilibrate. In some embodiments, the tobacco material is stored for at least about 12 hours, at least about 18 hours, at least about 24 hours, at least about 30 hours, or more after the first water addition step.

After the tobacco material is allowed to equilibrate, the tobacco material is generally separated into parts (e.g., stems are removed from the remaining portion of tobacco material) using a technique known as threshing. This separation can be accomplished, e.g., using a threshing mill with air separation. Example equipment that can be employed for this purpose can be provided, for example, by Cardwell Machine Company (Richmond, VA) or MacTavish Machine Manufacturing Company (Chesterfield, VA). Next, additional water is added to the threshed tobacco material to raise the water content of the tobacco material to, for example, about 30 to about 40% by weight, based on the total weight of the tobacco material. In some embodiments, water is added to the threshed tobacco in an amount sufficient to raise the water content of the tobacco material to at least about 30% by weight, at least about 32% by weight, at least about 34% by weight, at least about 36% by weight, at least about 38% by weight, or at least about 40% by weight, based on the total weight of the tobacco material.

Although not intended to be limiting, in some embodiments, the bulk tobacco material may be subjected to one or more additional treatments prior to the water addition and/or threshing steps. In some embodiments, for example, the tobacco material may be conditioned on a direct cylinder conditioning unit.

In some aspects of the present disclosure, the tobacco material in the mobile container may undergo one or more treatments and/or processing steps after the fermentation process has been completed. In some embodiments, for example, the fermented tobacco material is discharged from the mobile container after fermenting and subsequently cut and dried to form a tobacco material suitable for use in an oral product, such as a smokeless tobacco product. In certain embodiments, the fermented tobacco material can be doffed and cut to provide tobacco material strands of desired length and width. Such lengths and widths can vary, e.g., the lengths and widths typically designated as “fine cut,” “long cut,” and the like. In some embodiments, the water content of the dried, fermented tobacco material is about 15% to about 25% by weight, based on the total weight of the fermented tobacco material.

Tobacco compositions comprising one or more fermented tobacco materials described herein can be incorporated within oral products. The tobacco product to which the fermented tobacco materials of the present disclosure are added can vary, and may include any product configured or adapted to deliver tobacco or some component thereof to the user of the product. Example oral products may take various forms, including moist snuff (e.g., such as American fermented snuff, heat-treated Swedish-style snuff, and the like), dry snuff, snus, powders, shredded or particulate form, and/or in the form of pouches.

In some embodiments, oral products comprising the fermented tobacco materials of the present disclosure may be in the form of a mixture disposed within a moisture-permeable container (e.g., a water- permeable pouch). Such mixtures in the water-permeable pouch format are typically used by placing one pouch containing the mixture in the mouth of a human subject/user. Generally, the pouch is placed somewhere in the oral cavity of the user, for example under the lips, in the same way as moist snuff products are generally used. The pouch preferably is not chewed or swallowed. Exposure to saliva then causes some of the components of the mixture therein (e.g., flavoring agents and/or active ingredients, such as nicotine or tobacco) to pass through e.g., the water-permeable pouch and provide the user with flavor and satisfaction, and the user is not required to spit out any portion of the mixture. After about 10 minutes to about 60 minutes, typically about 15 minutes to about 45 minutes, of use/enjoyment, substantial amounts of the mixture have been ingested by the human subject, and the pouch may be removed from the mouth of the human subject for disposal. As explained in greater detail below, such embodiments are provided by way of example only, and pouched products prepared using the fermented tobacco materials of the present disclosure may include the mixture of ingredients in other forms as desired.

Non-limiting examples of suitable types of pouches are set forth in, for example, US Pat. Nos. 5,167,244 to Kjerstad and 8,931,493 to Sebastian et al.; as well as US Patent App. Pub. Nos. 2016/0000140 to Sebastian et al.; 2016/0073689 to Sebastian et al.; 2016/0157515 to Chapman et al.; and 2016/0192703 to Sebastian et al., each of which are incorporated herein by reference. Pouches can be provided as individual pouches, or a plurality of pouches (e.g., 2, 4, 5, 10, 12, 15, 20, 25 or 30 pouches) can be connected or linked together (e.g., in an end-to-end manner) such that a single pouch or individual portion can be readily removed for use from a one-piece strand or matrix of pouches.

The amount of material contained within each product unit, for example, a pouch, may vary. In some embodiments, the weight of the mixture within each pouch is at least about 50 mg, for example, from about 50 mg to about 2 grams, from about 100 mg to about 1.5 grams, or from about 200 mg to about 1000 mg. In some smaller embodiments, the weight of the mixture within each pouch may be from about 100 to about 300 mg. For a larger embodiment, the weight of the material within each pouch may be from about 300 mg to about 1300 mg. If desired, other components can be contained within each pouch. For example, at least one flavored strip, piece or sheet of flavored water dispersible or water soluble material (e.g., a breath-freshening edible film type of material) may be disposed within each pouch along with or without at least one capsule. Such strips or sheets may be folded or crumpled in order to be readily incorporated within the pouch. See, for example, the types of materials and technologies set forth in US Pat. Nos. 6,887,307 to Scott et al. and 6,923,981 to Leung et al.; and The EFSA Journal (2004) 85, 1-32; which are incorporated herein by reference.

A pouched product as described herein can be packaged within any suitable inner packaging material and/or outer container. See also, for example, the various types of containers for smokeless and oral types of products that are set forth in US Pat. Nos. 7,014,039 to Henson et al.; 7,537,110 to Kutsch et al.; 7,584,843 to Kutsch et al.; 8,397,945 to Gelardi et al., D592,956 to Thiellier; D594,154 to Patel et al.; and D625,178 to Bailey et al.; US Pat. Pub. Nos. 2008/0173317 to Robinson et al.; 2009/0014343 to Clark et al.; 2009/0014450 to Bjorkholm; 2009/0250360 to Bellamah et al.; 2009/0266837 to Gelardi et al.; 2009/0223989 to Gelardi; 2009/0230003 to Thiellier; 2010/0084424 to Gelardi; and 2010/0133140 to Bailey et al; 2010/0264157 to Bailey et al.; and 2011/0168712 to Bailey et al. which are incorporated herein by reference.

Many modifications and other embodiments of the disclosure will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing description. Therefore, it is to be understood that the disclosure is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

EXPERIMENTAL

The present disclosure is more fully illustrated by the following example, which is set forth to illustrate an embodiment of the present disclosure and is not to be construed as limiting thereof.

Example 1 40,000 pounds (18144 kg) of air-cured and fire-cured tobacco leaves were blended to provide a blended tobacco material. Water was added to the blended tobacco material to raise the water content of the tobacco material to about 20% to about 25% by weight, based on the total weight of the tobacco material. The water-added tobacco material was stored in a vessel for about 24 hours to allow the tobacco material to equilibrate. Next, the equilibrated tobacco material was threshed using a threshing mill to remove tobacco stems therefrom. Water was then added to the threshed tobacco material to raise the water content of the tobacco material to about 30% to about 40% by weight, based on the total weight of the tobacco material.

The threshed tobacco material and water were then placed in a wheeled stainless steel trailer and transported to a heating curing enclosure to ferment the tobacco material. The temperature within the curing enclosure was maintained at a temperature of about 70 °F to about 150 °F (about 21 to about 66 °C) for a period of 90 days and the tobacco material within the wheeled trailer was allowed to ferment. Periodically during the 90-day fermentation process, the wheeled trailer was removed from the curing enclosure and transported to an overhaul station for processing. During overhaul, the tobacco material was transferred from the wheeled trailer via a conveyor belt in the base of the trailer to a conveyor system for processing. During processing, the tobacco material was conveyed along a path defined by the conveyor system and returned to the wheeled trailer. Next, the wheeled trailer was transported back to the curing enclosure to allow the tobacco to ferment. This overhaul process was conducted twice a week for the duration of the 90-day fermentation.

After 90 days, the fermented tobacco material was discharged from the wheeled trailer, cut and dried to a moisture content of about 20% by weight to provide a finished good (cut and dried tobacco material) suitable for use in an oral product. The N-Nitrosonornicotine (NNN) content of the finished good was then measured and compared to the NNN content of a finished good prepared according to conventional fermentation processes where the tobacco material was fermented in barrels in 500 lb. quantities.

The NNN content is tested by extracting the tobacco material in an aqueous ammonium acetate solution and filtered into autosampler vials. The extracts are analyzed using high performance liquid chromatography -tandem mass spectrometry (HPLC-MS-MS). Detection is by multiple reaction monitoring (MRM) of the precursor ion to a product ion specific for the compound to be detected. Quantitation is achieved using an internal standard calibration of ten points.

The data is provided below in Table 1 and shows the maximum, minimum, and average NNN content for both samples.

Table 1

As shown in Table 1, the fermented tobacco material prepared using the bulk fermentation method described herein exhibited much lower average, minimum, and maximum NNN content when compared to the fermented tobacco material fermented in barrels.

Claims

1. A method of fermenting a bulk tobacco material, the method comprising: i) placing a bulk quantity of tobacco material in a mobile container; ii) storing the mobile container containing the tobacco material in a curing enclosure to ferment the tobacco material; iii) transporting the mobile container from the curing enclosure to a conveyor system; iv) moving the tobacco material from the mobile container to the conveyor system such that the tobacco material is conveyed along a path defined by the conveyor system and returned to the mobile container; and v) transporting the mobile container back to the curing enclosure to continue to ferment the tobacco material.

2. The method of claim 1, wherein steps iii) through v) are repeated periodically.

3. The method of claim 2, wherein steps iii) through v) are repeated at least once per week for period of time up to twelve weeks.

4. The method of claim 1, wherein steps iii) through v) are initiated when the tobacco material in the mobile container reaches a temperature of 100 °F or above.

5. The method of claim 1, wherein the mobile container comprises a moving floor to facilitate movement of the tobacco material from the mobile container to the conveyor system.

6. The method of claim 5, wherein the moving floor comprises a rubberized conveyor belt.

7. The method of claim 5, wherein the mobile container is a wheeled trailer with side walls defining an enclosed space for housing the tobacco material, an opening at the rear of the wheeled trailer adapted for dispensing the tobacco material onto the conveyor system, and at least one additional opening overlying the enclosed space for receiving the tobacco material from the conveyor system.

8. The method of claim 7, wherein the mobile container comprises a retractable cover for covering the at least one additional opening overlying the enclosed space.

9. The method of claim 1, wherein the conveyor system comprises a plurality of conveyor belts defining the path along which the tobacco materials travels.

10. The method of claim 1, wherein the curing enclosure is maintained at a temperature of about 70 °F to about 150 °F.

11. The method of claim 1, wherein the tobacco material is fermented in the curing enclosure for a period of about 10 to about 90 days.

12. The method of claim 1, wherein the tobacco material within the mobile container is a tobacco blend comprising an air-cured tobacco, a fire-cured tobacco, or a combination thereof.

13. The method of claim 1, wherein the tobacco material placed in the mobile container is a threshed tobacco material having a water content of about 30 to about 40% by weight, based on the total weight of the tobacco material.

14. The method of claim 1, further comprising treating the tobacco as follows prior to placing the tobacco material in the mobile container:

(c) threshing the tobacco to remove tobacco stem; and

15. The method of claim 1, further comprising discharging a fermented tobacco material from the mobile container, and cutting and drying the fermented tobacco material to form a tobacco material suitable for use in an oral product.

16. The method of claim 15, wherein the fermented tobacco material is dried to a water content of about 15% to about 25% by weight, based on the total weight of the fermented tobacco material.

17. The method of any one of claims 1 to 16, wherein the bulk quantity of tobacco material is at least 10,000 pounds of the tobacco material, such as about 30,000 to about 60,000 pounds of tobacco material.

18. A system for fermenting a bulk tobacco material, the system comprising: a mobile container configured to receive a tobacco material, the mobile container comprising a receiving end, a discharge end in spaced relation to the receiving end, and a moving floor capable of transporting the tobacco material from the receiving end to the discharge end; a conveyor system configured to transport the tobacco material, wherein the conveyor system is configured to receive the tobacco material from the discharge end of the mobile container via the moving floor, transport the tobacco material over a defined path, and discharge the tobacco material back into the receiving end of the mobile container; and a curing enclosure configured to receive the mobile container and designed to facilitate fermentation of the tobacco material within the mobile container.

19. The system of claim 18, wherein the conveyor system comprises a plurality of conveyor belts defining the path along which the tobacco materials travels.

20. The system of claim 19, wherein the plurality of conveyor belts are configured to receive the tobacco material from the discharge end of the mobile container, transport the tobacco material along the defined path, and discharge the tobacco material into the receiving end of the mobile container.

21. The system of claim 18, wherein the mobile container is a wheeled trailer with side walls defining an enclosed space for housing the tobacco material, an opening at the receiving end of the wheeled trailer adapted for dispensing the tobacco material onto the conveyor system, and at least one additional opening overlying the enclosed space for receiving the tobacco material from the conveyor system.

22. The system of claim 18, wherein the mobile container comprises a retractable cover for covering the at least one additional opening overlying the enclosed space.

23. The system of claim 18, wherein the moving floor comprises a rubberized conveyor belt.

24. The system of claim 18, wherein the curing enclosure comprises a heater configured to heat the tobacco material contained within the mobile container to facilitate fermentation of the tobacco material.

25. The system of any one of claims 18-24, wherein the mobile container is configured to receive at least 10,000 pounds of the tobacco material, such as about 30,000 to about 60,000 pounds of tobacco material.