WO2025248413A1

WO2025248413A1 - A method and system for producing a plant-based semi-finished material

Info

Publication number: WO2025248413A1
Application number: PCT/IB2025/055405
Authority: WO
Inventors: Giulio GOBBO; Fulvio Pastore; Paolo DAL CIN
Original assignee: Comas SpA
Current assignee: Comas SpA
Priority date: 2024-05-27
Filing date: 2025-05-26
Publication date: 2025-12-04
Anticipated expiration: 2026-11-27

Abstract

A system for producing a plant-based semi-finished material, comprising: a machine (P) for producing a continuous web (N) from at least one dry plant component; a cutting station (2), configured to divide the continuous web (N) into discrete portions (10, 20) by means of transverse cutting; at least one process machine (M) configured to further process said discrete portions (10, 20); conveyor means (4) configured to transfer the discrete portions (10, 20) from the cutting station (2) to said at least one process machine (M).

Description

DESCRIPTION

A METHOD AND SYSTEM FOR PRODUCING A PLANT-BASED SEMIFINISHED MATERIAL

Technical field

The present invention relates to a method and system for producing a plant-based semi-finished material, preferably intended for making smoking articles or for generating aerosols, i.e., made so as to be used for this purpose.

Background art

A “semi-finished” material is understood to mean that the material is not directly intended for consumption in the form of the invention, but it requires further physical and/or mechanical processing (e.g., the addition of additives, mechanical deformation or cutting).

Methods and machines are known for making plant-based continuous webs using a dry product, or a mixture of dried products, mixed with a binder and water in order to form a mixture (of the “slurry” type, having an almost liquid consistency, or of the “dough” type, having a doughy consistency), which is subsequently processed to form a continuous layer. Therefore, the continuous layer is dried creating the continuous web.

In known machines, the temporary storage of the continuous web in reels is provided following the formation thereof. The reels are subsequently unwound to feed a process machine, in particular a maker machine for making a sequence of rod-shaped segments.

Note that, disadvantageously, storage on reels often results in damage related to the requirement for space, the need for special handling (the reels are very heavy) and the risk that the web might break during the winding and unwinding operations.

Likewise, operating a line process that connects the machine for making the web to the machines intended to process the semi-finished material is extremely difficult due to the differences in speed between the two machines. In fact, the machines for making the web are slower than the machines intended to process the semi-finished material, but they produce webs having an elevated width, while the machines intended to process the semi-finished material are much faster while it requires a smaller width than the web being fed.

It is known, for example, from document WO2017/089545, to directly connect a machine for making a tobacco web to a plurality of maker machines for making continuous rods intended to make segments for smoking articles, by means of longitudinal cutting of the web into parallel continuous bands, each of which is fed to a respective maker machine. However, this solution requires adopting strict requirements relating to the speed of the two machines, which must necessarily be identical to each other. This generally results in operating the maker machines at a much lower speed than the maximum speed thereof, thus with reduced productivity.

The Applicant has found that by performing the transverse cutting of the continuous web exiting the machine for making the continuous web, it is possible to obtain discrete portions of the web, having appropriate dimensions and adapted to be subsequently processed in line by means of one or more machines intended to process the semi-finished material, eliminating the speed limitations, which would be present in the event of the absence of said transverse cutting.

Disclosure of the invention

Therefore, the present invention relates, in a first aspect thereof, to a method for producing a plant-based semi-finished material, comprising the following steps:

- making a continuous web from at least one dry plant component;

- dividing the continuous web into discrete portions by means of transverse cutting; - feeding and processing the discrete portions in at least one process machine configured to further process the discrete portions.

In a preferred embodiment, the process machine (or each process machine) is a machine for making a respective continuous rod, in which said continuous rod comprises a filling containing, or formed by, said discrete portions wrapped in an outer wrapping.

In an embodiment, the at least one dry plant component is tobacco based, e.g., at least partially in powder form.

In a different embodiment, the at least one dry plant component is nontobacco, e.g., selected from cellulose, straw, rapeseed or other nontobacco varieties, e.g., at least partially in powder form.

In a different embodiment, the at least one dry plant component comprises a first tobacco-based component and a second non-tobacco component, e.g., selected from cellulose, straw, rapeseed or other non-tobacco varieties, e.g., at least partially in powder form.

In an embodiment, the production of the continuous web from the at least one dry plant component is obtained by means of a casting process for a “slurry” type mixture, i.e., having a water content equal to or greater than 65%, in particular greater than 75%.

In a different embodiment, the production of the continuous web from the at least one dry plant component is obtained by means of a lamination process of rolling a “dough”-type mass, i.e., having a water content equal to or less than 65%, in particular less than 55%, even more particularly less than 50%, e.g., comprised between 25% and 35%.

The continuous web preferably has a width comprised between 1 and 2.5 m, preferably comprised between 1 .5 and 2 m.

In an embodiment, the step of dividing the continuous web into discrete portions by means of transverse cutting is performed by dividing the continuous web into sheets. Preferably, each sheet has a main extension dimension comprised between 0.5 and 3 m, more preferably comprised between 1 and 2.5 m and even more preferably comprised between 1 .5 and 2 m.

Each sheet preferably has a main extension dimension having a width, transversely to the main extension dimension, which is smaller than the width of the continuous web. Said smaller width allows sequentially feeding the sheets to one or more process machines, allowing operating said machine or said machines at the optimized speed thereof, which may be much higher than the feed speed of the continuous web.

In a different embodiment, the step of dividing the continuous web into discrete portions by means of transverse cutting is performed by dividing the continuous web into shreds, preferably in strip form. Preferably, each shred has a length comprised between 10 and 800 mm, more preferably comprised between 15 and 30 mm, and/or a width comprised between 1 and 10 mm, more preferably comprised between 1 .5 and 3 mm.

The discrete portions are preferably fed directly to the at least one process machine, i.e., by means of operating only the transport steps, but without further chemical-physical or mechanical processes, in particular, without further cutting steps.

The discrete portions are preferably fed directly to at least one machine for making a respective continuous rod, i.e., by means of operating only the transport steps, or at most, with the application of additives, but without further mechanical processes, in particular, without further cutting steps.

In an embodiment, the maker machine (or each maker machine) is a single-line machine, i.e., a “single-rod” machine”.

In a different embodiment, the maker machine (or each maker machine) is a multiple-line machine, i.e., a “multi-rod” machine (typically, a double-line machine).

In a different embodiment, the discrete portions (preferably in the solution in which they are the stated sheets) can be crimped before being fed to the process machine, or alternatively, the process machine comprises a crimping station at the inlet configured to crimp the sheets fed thereto.

Alternatively, the method according to the invention can comprise a crimping step of crimping the continuous web upstream of the division, by means of transverse cutting, of the continuous web into discrete portions.

Said crimping is preferably performed at a web speed comprised between 10 m/min and 40 m/min, more preferably comprised between 20 m/min and 30 m/min.

The step of dividing the continuous web into discrete portions by means of transverse cutting is preferably preceded by a step of dividing the continuous web by means of longitudinal cutting into parallel continuous bands, preferably between 2 and 5 in number. Therefore, the step of dividing the continuous web into discrete portions by means of transverse cutting is performed, in this case, on the continuous bands.

Thus, each continuous band can undergo cutting into segments, defining the stated sheets (with an exclusively transverse action, keeping the same width, or alternatively with a combined longitudinal-transverse cutting action, also to reduce the width), or shredding in the stated strips. In this case, the advantage is having a number of separate flows of sheets or shreds, corresponding to the number of continuous bands processed from the continuous web.

In the case of dividing into sheets with a combined longitudinal-transverse cut, each sheet preferably has a main extension dimension having a width, transversely to the main extension dimension, which is smaller than the width of the continuous web. Said smaller width allows sequentially feeding the sheets to one or more process machines, allowing operating said machine or said machines at the optimized speed thereof, which may be much higher than the feed speed of the continuous web.

In said case, the transverse cutting performed on the continuous bands is preferably performed by means of a respective cutting device on each continuous band.

The cutting devices for cutting the continuous bands are preferably arranged in mutually offset positions along the longitudinal extension direction of the continuous bands. The cutting devices for cutting the continuous bands are preferably arranged in coplanar positions and mutually offset along the longitudinal extension direction of the continuous bands.

This allows optimizing the system layout, preventing cutting devices from being arranged mutually adjacent, with the risk of poor exploitation of space. Furthermore, this allows optimally collecting the discrete portions, by means of respective conveyors spaced apart from one another.

Furthermore, the cutting devices for cutting the continuous bands are preferably independent of each other and/or controlled independently of each other.

Furthermore, in an embodiment, the crimping step of crimping the continuous web is performed upstream of the division of the continuous web by means of longitudinal cutting into parallel continuous bands, but in any case downstream of the exit of the continuous web from the machine for producing the continuous web.

In a different embodiment, the crimping step of crimping the web is performed between the dividing step of dividing the continuous web by means of longitudinal cutting into parallel continuous bands and the successive transverse cutting step, therefore, it is performed on the parallel continuous bands. In this circumstance, the crimping can in any case be performed by means of a single crimping device acting simultaneously on all the parallel continuous bands or by means of a plurality of crimping devices, each acting on a respective parallel continuous band. In this latter solution, the crimping devices can be independent and/or independently controllable of each other. Furthermore, the crimping devices can be arranged in mutually offset positions along the longitudinal extension direction of the continuous bands.

In an embodiment, the step of feeding and processing the discrete portions in at least one process machine is performed by feeding the discrete portions to a plurality of process machines, in particular by feeding the discrete portions obtained from each continuous band to a respective machine.

These machines are preferably separate and independent of each other. Alternatively, the step of feeding and processing the discrete portions in at least one process machine is performed by feeding the discrete portions to a single process machine.

In a further embodiment, the step of feeding and processing the discrete portions in at least one process machine is performed by feeding all the discrete portions obtained from the entire continuous web to a plurality of process machines by means of division into separate flows, said machines preferably being separate and independent of each other. This is also obtainable, besides following the aforesaid division of the continuous web into parallel continuous bands, by means of a different solution, comprising the division, into separate flows, of the entire flow of discrete portions obtained from the entire continuous web. Said solution is particularly conceived, for example, in the case of shredding the web into strips having a finite length.

According to an embodiment, the continuous web is processed by means of the transverse cutting of the continuous web in line with the machine for making the web. In other words, the system has the at least one process machine arranged downstream of the machine for making the continuous web and connected in line thereto.

In a different embodiment, between the step of making the continuous web, and the step of dividing the continuous web into discrete portions by means of transverse cutting, there is interposed a step of winding the web onto at least one reel and subsequent unwinding of the web from said reel. This allows achieving the same advantages as the known solutions using storage on reels (processing flexibility, time deferral between the steps of producing the web and making the continuous rod), while allowing benefiting from the advantages of the invention, with particular reference to the adoption of optimized speeds for the at least one process machine, regardless of the width of the reel and the unwinding speed thereof. The step of making the continuous web is preferably obtained by means of a machine having a line speed, and/or operating at a speed, lower than 50 m/min, preferably lower than 40 m/min and even more preferably lower than 30 m/min. In other words, the machine for making the continuous web can operate at optimized capacity.

Furthermore, the at least one process machine preferably has a line speed, and/or operates at a speed, higher than 100 m/min, preferably higher than 150 m/min and even more preferably higher than 200 m/min. In other words, the at least one process machine can also operate at capacities differing greatly from the machine for making the continuous web.

The present invention also relates, in a first aspect thereof, to a system for producing a plant-based semi-finished material, comprising:

- a machine for producing a continuous web from at least one dry plant component;

- a cutting station, configured to divide the continuous web into discrete portions by means of transverse cutting;

- at least one process machine configured to further process said discrete portions;

- conveyor means configured to transfer the discrete portions from the cutting station to said at least one process machine.

The at least one process machine is preferably a machine for making a continuous rod, configured to receive and process the discrete portions and make a continuous rod comprising a filling containing, or formed by, said discrete portions wrapped in an outer wrapping.

In an embodiment, the cutting station comprises at least one transverse cutting blade operated and/or operable for dividing the continuous web into sheets, where each sheet preferably has a main extension dimension comprised between 0.5 and 3 m, more preferably comprised between 1 and 2.5 m and even more preferably comprised between 1 .5 and 2 m.

In a different embodiment, the cutting station comprises a shredder, preferably a rotating shredder, configured to divide the continuous web into shreds, preferably in the form of strips, where each shred preferably has a length comprised between 10 and 800 mm, more preferably comprised between 15 and 30 mm, and/or a width comprised between 1 and 10 mm, more preferably comprised between 1 .5 e 3 mm.

Preferably, the rotating shredder comprises at least one roller (preferably a pair of opposing rollers) provided with cutting edges or circumferential cutting protrusions and axial cutting protrusions or blades, where the cutting edges or circumferential cutting protrusions preferably shape the long sides of the strip shreds, while the axial cutting protrusions or blades shape the short sides of the strip shreds. Therefore, the strip shreds are preferably generated with a main extension direction parallel to the inlet direction of the continuous web in the shredder.

The conveyor means preferably comprise one or more continuous conveyors, in particular belt conveyors, which preferably receive the shreds by gravity (or alternatively the sheets) and carry them to the at least one machine for making the continuous rod.

In an embodiment, the system further comprises a crimping device, between the machine for producing the continuous web and the cutting station, configured to crimp the continuous web.

The crimping device is preferably configured to operate (continuously) at a web speed comprised between 10 m/min and 40 m/min, more preferably comprised between 20 m/min and 30 m/min.

In an embodiment, a dividing station is provided, between the machine for producing the continuous web and the cutting station, for dividing the continuous web into parallel continuous bands, preferably between 2 and 5 in number, so that the cutting station makes the discrete portions by dividing the continuous bands.

In this configuration, the cutting station preferably comprises a plurality of cutting devices, each arranged and/or configured to operate on a respective continuous band. The cutting devices for cutting the continuous bands are preferably arranged in mutually offset positions along the longitudinal extension direction of the continuous bands and are preferably independent of each other and/or controllable independently of each other.

Alternatively, the cutting station comprises a single cutting device configured to perform the simultaneous transverse cutting on all the parallel continuous bands.

Furthermore, in an embodiment, the crimping device is arranged upstream of the dividing station for dividing the continuous web into parallel continuous bands, but in any case downstream of the exit of the continuous web from the machine for producing the continuous web.

In a different embodiment, the crimping device is arranged between the dividing station for dividing the continuous web into parallel continuous bands and the subsequent cutting station, so as to crimp the parallel continuous bands. In this circumstance, the crimping can in any case be performed by means of a single crimping device acting simultaneously on all the parallel continuous bands or by means of a plurality of crimping devices, each acting on a respective parallel continuous band. In this latter solution, the crimping devices can be independent and/or independently controllable of each other. Furthermore, the crimping devices can be arranged in mutually offset positions along the longitudinal extension direction of the continuous bands.

In these solutions using the division of the continuous web into parallel continuous bands, the system can comprise a plurality of process machines, preferably separate and independent from one another. In said configuration, the conveyor means are configured to transfer the discrete portions obtained from each continuous band to a respective process machine.

In a further different embodiment, without the division of the continuous web into parallel continuous bands, the cutting station comprises a single cutting device configured to perform the transverse cutting of the entire continuous web.

In a different embodiment, comprising a single process machine, the conveyor means can be configured to transfer the discrete portions obtained from the entire continuous web to said process machine.

In a further different embodiment, comprising a plurality of process machines, preferably separate and independent from one another, the conveyor means are configured to transfer the discrete portions obtained from the entire continuous web to said machines, preferably by dividing the discrete portions into separate flows. In other words, the transverse cutting (and possibly also the longitudinal cutting) makes a single flow of discrete portions, which can be separated into flows to be directed to the respective process machines.

Further features and advantages of the present invention will become more apparent from the following indicative and thus non-limiting description of an embodiment of a method and system for producing a plant-based semi-finished material according to the invention.

Brief description of drawings

This description will be presented below with reference to the accompanying drawings provided purely by way of indicative and, therefore, non-limiting purposes, in which: figure 1 shows a diagrammatic representation of a first embodiment of a system according to the invention; figure 2 shows a diagrammatic representation of a second embodiment of a system according to the invention;

- figure 3 shows a diagrammatic representation of a third embodiment of a system according to the invention;

- figure 4 shows a diagrammatic representation of a fourth embodiment of a system according to the invention;

- figure 5 shows a diagrammatic representation of a fifth embodiment of a system according to the invention; - figure 6 shows a diagrammatic representation of a sixth embodiment of a system according to the invention.

- figure 7 shows a diagrammatic representation of a seventh embodiment of a system according to the invention.

Detailed description of preferred embodiments of the invention

The method for producing a plant-based semi-finished material according to the invention will now be described in an embodiment thereof with reference to the system 1 used to implement it.

Figure 1 shows a first embodiment of the system 1 , illustrated in diagrammatic form.

The system 1 comprises a machine “P” for producing a continuous web “N” from at least one dry plant component.

In an embodiment, the machine “P” is configured to make the continuous web “N” by means of a casting process, obtained by making a mixture having a liquid or semi-liquid consistency, with a water content equal to or greater than 65%, in particular, greater than 75%. According to said solution, the mixture is dispensed from a container or hopper onto a conveyor belt forming a continuous layer, which crosses a dryer, at the end of which the continuous web comes out.

In a different embodiment, the machine “P” is configured to produce the continuous web “N” by means of a lamination process for a mixture having a doughy consistency (i.e. with a water content equal to or lower than 65%, in particular, lower than 55%, even more particularly, lower than 50%, e.g. between 25% and 35%) by means of one or more lamination steps, making a continuous layer, which crosses a dryer, at the end of which the continuous web comes out.

The invention is applicable to different kinds of continuous webs. For example, the at least one dry plant component can be tobacco based, e.g. at least partially in powder form, or of the non-tobacco type, e.g. selected from cellulose, straw, rapeseed or other non-tobacco varieties, e.g. at least partially in powder form, or it can comprise a first tobacco-based component and a second non-tobacco component, e.g., selected from cellulose, straw, rapeseed or other non-tobacco varieties, e.g. at least partially in powder form.

The continuous web “N” exiting the machine “P” preferably has a width comprised between 1 and 2.5 m, preferably comprised between 1.5 and 2 m.

Downstream of the machine “P”, the system 1 comprises a cutting station 2, configured to divide the continuous web “N” into discrete portions by means of transverse cutting.

In the embodiment in figure 1 , the discrete portions are in the form of sheets 10 the extension of which is greater than a minimum value. For example, each sheet 10 can have a rectangular shape with a main extension dimension comprised between 0.5 and 3 m, more preferably comprised between 1 and 2.5 m and even more preferably comprised between 1 .5 and 2 m.

Each sheet 10 can have a minimum surface suitable for defining it as such. For example, said minimum surface is 0.5 m², preferably 1 m².

In this embodiment, the cutting station 2 (not illustrated in detail) can comprise at least one cutting blade suitable for the transverse cutting of the continuous web “N”, preferably along at least one transverse cutting line 3, preferably perpendicular to the feed direction of the continuous web “N” (coinciding with the main extension direction of the continuous web “N”).

Said cutting blade can be a blade arranged on a rotatable cutting member, for example a cutting roller supporting one or more of said blades, or a blade provided with a linear or tracking cutting movement.

At least one process machine “M” is arranged downstream of the cutting station 2, configured to further process the sheets 10. In particular, the process machine “M” is configured to receive and process the sheets 10 according to one or more specific processings, in particular, chemicalphysical processings (application of additional materials or heat or chemical treatments) or mechanical processings (contouring, cutting, compressions).

At least one process machine “M” of the maker type is preferably arranged downstream of the cutting station 2, configured to make at least one continuous rod (not illustrated). In particular, the process machine “M” of the maker type is configured to receive and process the sheets 10 and make a continuous rod comprising a filling containing said discrete portions (or formed therefrom), wrapped in an outer wrapping, preferably made of paper.

For example, said process machine “M” of the maker type can be a traditional machine provided with a forming beam with progressive forming of the tubular wrapping about the filling material.

In said situation, the sheets 10 can preferably be transferred from the cutting station 2 to the process machine “M” by means of special conveyor means 4, e.g., of the conveyor belt type.

At least one section of the conveyor means 4 is preferably parallel to the main extension direction of the sheets 10 so that the sheets 10 are carried in a longitudinal direction.

In the illustrated embodiment, the sheets 10 are separated from the continuous web “N” by means of transverse cutting so that each sheet 10 has the main extension direction thereof perpendicular to the longitudinal direction of the continuous web “N”.

Each sheet 10 can be sent and processed in the process machine “M” without further intermediate process steps or, alternatively, it can undergo crimping by means of a special crimping station (not illustrated), arranged at the inlet of the process machine “M” and/or along the extension of the conveyor means 4.

In an embodiment, the crimping of each sheet 10 can be generated by means of a cutting device (not illustrated as it is of the known type) operating upstream of the cutting station 2.

The embodiment in figure 2 differs from the embodiment in figure 1 in that it comprises, between the machine “P” for producing the continuous web “N” and the cutting station 2, a dividing station 5 for dividing the continuous web “N” into parallel continuous bands 8, preferably between 2 and 5 in number, so that the successive cutting station 2 makes the discrete portions (sheets) 10 by means of transversely dividing the continuous bands 8.

The dividing station 5 for dividing the continuous web “N” into parallel continuous bands 8 preferably comprises one or more longitudinal cutting blades 6 configured to make one or more corresponding longitudinal cutting lines 7 parallel to one another on the continuous web “N”. Said longitudinal cutting blades 6 can be rotating blades with an axis transverse to the feed direction of the continuous web “N”.

In the embodiment in figure 2, the longitudinal cutting blades 6 are two in number and make three parallel continuous bands 8. Said number nonetheless represents a specific embodiment.

In the embodiment in figure 2, each continuous band 8 subjected to transverse cutting generates a corresponding sequence of sheets 10, which can be rectangular in shape having a main extension direction parallel to the feed direction (specific solution in figure 2) or perpendicular to the feed direction.

Furthermore, in the embodiment in figure 2, each sequence of sheets 10 is sent as input (by the conveyor means) to a respective process machine “M” for further processing.

Also in this embodiment, each sheet 10 can be sent and processed in the respective process machine “M” without further intermediate process steps, or alternatively, it can be subjected to crimping by means of a special crimping station (not illustrated) arranged at the inlet of the process machine “M” and/or along the extension of the conveyor means.

In an embodiment, the crimping of each sheet 10 can be generated by means of at least one cutting device (not illustrated being of the known type) operating upstream of the cutting station 2. In particular, the cutting device can be arranged upstream of the dividing station 5 for dividing the continuous web “N” into parallel continuous bands 8 (in this case, the crimping device is preferably one for the entire width of the continuous web “N”) or downstream of the dividing station 5 for dividing the continuous web “N” into parallel continuous bands 8 but upstream of the cutting station 2 (in this case each continuous band 8 can be processed by means of a respective crimping device).

The embodiment in figure 3 differs from the embodiment in figure 2 in that it has a number of process machines “M” smaller than the number of parallel continuous bands 8, in particular a single process machine “M”. Preferably, with a single process machine “M” the number of parallel continuous bands 8 is preferably equal to two or three.

In the specific embodiment in figure 3, the sequences of sheets 10 obtained from the transverse separation of the parallel continuous bands 8 are joined together in a single sequence of sheets entering the single process machine “M”. Thus, it is possible to adapt the operation at a lower speed of machine “P” for producing the continuous web “N” to the operation at a higher speed of the process machine “M”, connecting them directly in line.

The embodiment in figure 4 differs from the embodiment in figure 1 in that the cutting station 2 comprises a shredder, preferably a rotating shredder, configured to divide the continuous web “N” into shreds 20 preferably in strip form, each shred preferably having a length comprised between 10 and 800 mm, more preferably comprised between 15 and 30 mm, and/or a width comprised between 1 and 10 mm, more preferably comprised between 1 .5 and 3 mm.

The shredder is preferably made by means of a pair of shredder rollers 9 provided with cutting edges or circumferential cutting protrusions and blades, or axial cutting protrusions, where the cutting edges or circumferential cutting protrusions preferably shape the long sides of the strip shreds, while the axial cutting protrusions or blades shape the short sides of the strip shreds. Therefore, the strip shreds 20 are preferably generated with a main extension direction parallel to the inlet direction of the continuous web in the shredder.

In an embodiment, the two shredder rollers 9 are set side-by-side and receive the web “N” from above, causing the shreds 20 to be released, by falling, onto the conveyor means 4.

Thus, the shreds 20 are carried by the conveyor means 4 to a process machine “M” for further processing.

Then, the shreds 20 are preferably carried, by the conveyor means 4, to a process machine “M” of the maker type where they at least partially define a filling wrapped in an outer tubular wrapping of a continuous rod.

In the specific embodiment in figure 4, the conveyor means take the shreds 20 exiting the shredder, carrying them along a transverse direction, preferably perpendicular to the longitudinal direction of the continuous web “N”.

Also in this embodiment, it is possible to consider the same aforesaid crimping options.

The embodiment in figure 5 differs from the embodiment in figure 4 in that it shows, by analogy with figures 2 and 3, the longitudinal division of the continuous web “N” into parallel continuous bands 8, in particular by means of one or more longitudinal cutting blades 6 configured to make one or more corresponding longitudinal cutting lines 7 parallel to one another on the continuous web “N”, so that the successive cutting station 2 makes the discrete portions (shreds) 20 by means of transversely dividing the continuous bands 8. Furthermore, in this embodiment, the system 1 comprises a plurality of process machines “M”.

Furthermore, in the embodiment in figure 5, the cutting station 2 comprises a plurality of cutting devices 2 (shredders), each arranged and/or configured to operate on a respective continuous band 8. Therefore, each shredder 2 produces a corresponding flow of shreds 20 preferably conveyed, in the transverse direction, preferably perpendicular to the longitudinal direction of the continuous web “N” by the conveyor means 4. The shredders 2 arranged on the respective parallel continuous bands 8 are preferably arranged in mutually offset positions along the longitudinal extension direction of the continuous bands 8.

Furthermore, the shredders 2 are independent of each other and/or controllable independently of each other.

The embodiment in figure 6 differs from the embodiment in figure 5 in that it does not have the longitudinal division of the continuous web “N” into parallel continuous bands and in that it only has one shredder 2 configured to cut the entire continuous web “N” into shreds 20, which are sent to the plurality of process machines “M” by separate flows exiting or downstream of the shredder 2. Also in this case, the process machines “M” are preferably separate and independent of each other.

The embodiment in figure 7 differs from the embodiment in figure 5 in that it has a single process machine (or in any case a smaller number of process machines than the number of shredders and parallel continuous bands) and in that the flows exiting different shredders 2 are joined to one another by conveyor means 4 in a single flow being fed to one same process machine “M”, in particular, all the flows coming from the shredders 2 are joined in a single flow being fed to a single process machine “M”.

The present invention achieves the set objects, overcoming the drawbacks reported in the prior art.

Indeed, by means of the transverse cutting of the continuous web, it is also possible to operate one or more process machines, arranged downstream, at an optimized speed regardless of the actions carried out upstream, e.g. independently of the machine for making the continuous web, which can be connected in line with the at least one process machine and also operate at an optimized speed thereof.

Claims

1. A method for producing a plant-based semi-finished material, comprising the following steps:

- making a continuous web (N) from at least one dry plant component;

- dividing the continuous web (N) into discrete portions (10, 20) by means of transverse cutting;

- feeding and processing the discrete portions (10, 20) in at least one process machine (M) configured to further process said discrete portions (10, 20).

2. A method according to claim 1 , wherein said process machine (M) is a maker machine (M) for making a continuous rod, wherein said continuous rod comprises a filling containing, or formed by, said discrete portions (10, 20) wrapped in an outer wrapping.

3. A method according to claim 1 or 2, wherein the step of making the continuous web (N) makes a continuous web (N) having a width comprised between 1 and 2.5 m, preferably comprised between 1.5 and 2 m.

4. A method according to any one of the preceding claims, wherein said step of making the continuous web (N) is performed by means of a casting method for a slurry-type material, in particular, having a water content equal to or greater than 65%, in particular, greater than 75%.

5. A method according to any one of the preceding claims from 1 to 3, wherein the step of making the continuous web (N) is performed by laminating a mixture preferably having a water content lower than 65%, more preferably lower than 50%.

6. A method according to any one of the preceding claims, wherein said step of dividing the continuous web (N) into discrete portions (10, 20) by means of transverse cutting is performed by dividing the continuous web (N) into sheets (10), each sheet (10) preferably having a main extension dimension comprised between 0.5 and 3 m, more preferably comprised between 1 and 2.5 m and even more preferably comprised between 1 .5 and 2 m.

7. A method according to any one of the preceding claims from 1 to 5, wherein said step of dividing the continuous web (N) into discrete portions (10, 20) by means of transverse cutting is performed by dividing the continuous web (N) into shreds (20), preferably in strip form, each shred (20) preferably having a length comprised between 10 and 800 mm, more preferably comprised between 15 and 30 mm, and/or a width comprised between 1 and 10 mm, more preferably comprised between 1 .5 and 3 mm.

8. A method according to any one of the preceding claims, further comprising a step of crimping the continuous web (N) upstream of the division, by transverse cutting the continuous web (N) into discrete portions (10, 20), said crimping preferably being performed at a web speed comprised between 10 m/min and 40 m/min, more preferably comprised between 20 m/min and 30 m/min.

9. A method according to any one of the preceding claims, wherein said step of dividing the continuous web (N) into discrete portions (10, 20) by means of transverse cutting is preceded by a step of dividing the continuous web (N) by means of longitudinal cutting into parallel continuous bands (8), preferably between 3 and 6 in number, said step of dividing the continuous web (N) into discrete portions (10, 20) by means of transverse cutting being performed on said continuous bands (8).

10. A method according to claim 9, wherein said transverse cutting on said continuous bands (8) is performed by means of a respective cutting device (2) on each continuous band (8), and wherein the cutting devices (2) of the continuous bands (8) are preferably arranged in mutually offset positions along the longitudinal extension direction of the continuous bands (8) and they are preferably independent of each other and/or controlled independently of each other.

11. A method according to claim 10, wherein the step of feeding and processing the discrete portions (10, 20) in at least one process machine (M) is performed by feeding the discrete portions (10, 20) to a plurality of process machines (M) configured to perform respective processing steps, said process machines (M) preferably being separate and independent of each other, and wherein the discrete portions (10, 20) obtained from each of said continuous bands (8) are fed to a respective one of said process machines (M).

12. A method according to claim 11 , wherein said process machines (M) are maker machines (M) for making a respective continuous rod and wherein the discrete portions (10, 20) obtained from each of said continuous bands (8) are fed to a respective one of said maker machines (M).

13. A method according to any one of the preceding claims, wherein the step of feeding and processing the discrete portions (10, 20) in at least one process machine (M) is performed by feeding the discrete portions (10, 20) to a single process machine (M), preferably a single-line maker machine (M).

14. A method according to any one of the preceding claims from 1 to 12, wherein the step of feeding and processing the discrete portions (10, 20) in at least one process machine (M) is performed by feeding all the discrete portions (10, 20) obtained from the entire continuous web (N) to a plurality of process machines (M) by means of division into separate flows, said process machines (M) preferably being separate and independent from one another.

15. A method according to claim 14, wherein said process machines (M) are maker machines (M) for making a respective continuous rod.

16. A method according to any one of the preceding claims, further comprising, between the step of making the continuous web (N) and the step of dividing the continuous web (N) into discrete portions (10, 20) by means of transverse cutting, a winding step of winding the web onto at least one reel and subsequent unwinding of the web from said reel.

17. A method according to any one of the preceding claims, wherein said step of making the continuous web (N) is obtained by means of a machine (P) having a line speed, and/or operating at a speed, lower than 50 m/min, preferably lower than 40 m/min and even more preferably lower than 30 m/min, and/or wherein said at least one process machine (M) has a line speed and/or operates at a speed higher than 100 m/min, preferably higher than 150 m/min and even more preferably higher than 200 m/min.

18. A system for producing a plant-based semi-finished material, comprising:

- a machine (P) for producing a continuous web (N) from at least one dry plant component;

- a cutting station (2), configured to divide the continuous web (N) into discrete portions (10, 20) by means of transverse cutting;

- at least one process machine (M) configured to further process said discrete portions (10, 20);

- conveyor means (4) configured to transfer the discrete portions (10, 20) from the cutting station (2) to said at least one process machine (M).

19. A system according to claim 18, wherein said process machine (M) is a maker machine (M) for making a continuous rod, configured to receive and process the discrete portions (10, 20) and make a continuous rod comprising a filling containing, or formed by, said discrete portions (10, 20) wrapped in an outer wrapping.

20. A system according to claim 18 or 19, wherein said cutting station (2) comprises at least one transverse cutting blade implemented and/or implementable for dividing the continuous web (N) into sheets (10), each sheet (10) preferably having a main extension dimension comprised between 0.5 and 3 m, more preferably comprised between 1 and 2.5 m and even more preferably comprised between 1 .5 and 2 m.

21. A system according to claim 18 or 19, wherein said cutting station (2) comprises a shredder, preferably a rotating shredder, configured to divide the continuous web (N) into shreds (20), preferably in strip form, each shred (20) preferably having a length comprised between 10 and 800 mm, more preferably comprised between 15 and 30 mm, and/or a width comprised between 1 and 10 mm, more preferably comprised between 1.5 and 3 mm.

22. A system according to any one of the preceding claims from 18 to 21 , further comprising, between the machine (P) for producing the continuous web (N) and the cutting station (2), a crimping device configured to crimp the continuous web (N), said crimping device preferably being configured to operate at a web speed comprised between 10 m/min and 40 m/min, more preferably comprised between 20 m/min and 30 m/min.

223. A system according to any one of the preceding claims from 18 to 22, further comprising, between the machine (P) for producing the continuous web (N) and the cutting station (2), a dividing station (5) for dividing the continuous web (N) into parallel continuous bands, (8), preferably between 2 and 5 in number, so that the cutting station (2) makes the discrete portions (10, 20) by means of transversely dividing said continuous bands (8).

24. A system according to claim 23, wherein the cutting station (2) comprises a plurality of cutting devices (2), each arranged and/or configured to operate on a respective continuous band (8), and wherein the cutting devices (2) for cutting the continuous bands (8) are preferably arranged in mutually offset positions along the longitudinal extension direction of the continuous bands (8) and are preferably independent of each other and/or controllable independently of each other.

25. A system according to claim 24, comprising a plurality of process machines (M) configured to perform respective processing steps, said process machines (M) preferably being separate and independent of each other, and wherein the conveyor means (4) are configured to transfer the discrete portions (10, 20) obtained from each of said continuous bands (8) to a respective one of said process machines (M).

26. A system according to any one of the preceding claims from 18 to 25, comprising a single process machine (M), and wherein the conveyor means (4) are configured to transfer the discrete portions (10, 20) obtained from the entire continuous web (N) to said process machine (M).

27. A system according to any one of the preceding claims from 18 to 25, comprising a plurality of process machines (M), preferably separate and independent of each other, and wherein the conveyor means (4) are configured to transfer the discrete portions (10, 20) obtained from the entire continuous web (N) to said process machines (M), preferably by dividing the discrete portions into separate flows.

28. A system according to any one of the preceding claims from 25 to 27, wherein said process machines (M) are maker machines (M) for making a respective continuous rod.