Method of making oral pouch products

Abstract

Provided is a method of manufacturing a pouched, oral tobacco product including a porous membrane having a liner and an inner filling material. The inner filling material includes loose, fibrous tobacco material and tobacco beads formed from tobacco fines and dust which are too small to be included in traditional pouched tobacco products. The tobacco beads are extruded and spheronized.

We claim: 
     
         1 . A method of making a pouched, oral tobacco product comprising:
 spheronizing and/or extruding a plurality of tobacco beads;   mixing the plurality of tobacco beads with loose, fibrous tobacco material to form an inner filling material;   forming a pouch from a porous membrane material;   adding a dissolvable liner to the pouch to form a lined pouch;   placing the inner filling material in the lined pouch; and   sealing the lined pouch to form a pouched, oral tobacco product.   
     
     
         2 . The method of  claim 1 , wherein each of the tobacco beads includes an agglomeration of tobacco fines, water and an optional binder, and wherein the optional binder is sugar beet fiber. 
     
     
         3 . The method of  claim 2 , wherein the ratio of the agglomeration of tobacco fines to water in each of the tobacco beads is about 1:4 to about 4:1. 
     
     
         4 . The method of  claim 1 , wherein each of the tobacco beads further includes a coating, and wherein the coating is a time release coating. 
     
     
         5 . The method of  claim 1 , wherein the tobacco beads comprise a majority amount of tobacco fines having a particle size of less than about 60 mesh, the tobacco fines being dispersed uniformly throughout the entirety of each tobacco bead, the tobacco beads having a moisture content of about 0.5% to about 25%, and the tobacco beads included in an amount of about 10% to about 95% by weight based on the weight of the pouched, oral tobacco product. 
     
     
         6 . The method of  claim 1 , wherein the tobacco beads include tobacco fines in an amount of about 5 wt % to about 100 wt %. 
     
     
         7 . The method of  claim 1 , wherein the pouched, oral product is made during a high speed pouch filling operation. 
     
     
         8 . The method of  claim 1 , wherein the tobacco beads each have a diameter of about 0.1 mm to about 2.5 mm. 
     
     
         9 . The method of  claim 1 , wherein the liner is dissolvable in saliva. 
     
     
         10 . The method of  claim 1 , wherein the tobacco beads further include a binder. 
     
     
         11 . The method of  claim 10 , wherein the binder is sugar beet fiber. 
     
     
         12 . The method of  claim 4 , wherein the coating is a time release coating. 
     
     
         13 . The method of  claim 1 , wherein the coating includes at least one flavorant selected from the group consisting of lavender, cinnamon, cardamom, apium graveolens, fenugreek, cascarilla, sandalwood, bergamot, geranium, honey essence, rose oil, vanilla, lemon oil, orange oil, mint oils, cassia, caraway, cognac, jasmine, chamomile, menthol, cassia, ylang-ylang, sage, spearmint, ginger, coriander, coffee, combinations thereof, and combinations thereof. 
     
     
         14 . The method of  claim 13 , wherein the at least one flavorant is included in each of the tobacco beads in an amount of about 0.1% to about 10% by weight of the weight of each of the tobacco beads. 
     
     
         15 . The method of  claim 1 , wherein the liner includes at least one flavorant selected from the group consisting of lavender, cinnamon, cardamom, apium graveolens, fenugreek, cascarilla, sandalwood, bergamot, geranium, honey essence, rose oil, vanilla, lemon oil, orange oil, mint oils, cassia, caraway, cognac, jasmine, chamomile, menthol, cassia, ylang-ylang, sage, spearmint, ginger, coriander, coffee and combinations thereof. 
     
     
         16 . The method of  claim 15 , wherein the at least one flavorant is included in the liner in an amount of about 0.1% to about 10% by weight of the weight of the liner. 
     
     
         17 . The method of  claim 1 , wherein the pouched, oral tobacco product has a maximum length of less than about two inches and a maximum thickness of less than about two inches. 
     
     
         18 . The method of  claim 1 , wherein the liner is made of a material selected from the group consisting of cellulosic materials, gums, polymers, starches, proteins, food grade materials, such as polysaccharide, protein films, porous papers and fabrics, synthetic polymers, and combinations thereof. 
     
     
         19 . The method of  claim 18 , wherein the liner includes at least one flavorant selected from the group consisting of lavender, cinnamon, cardamom, apium graveolens, fenugreek, cascarilla, sandalwood, bergamot, geranium, honey essence, rose oil, vanilla, lemon oil, orange oil, mint oils, cassia, caraway, cognac, jasmine, chamomile, menthol, cassia, ylang-ylang, sage, spearmint, ginger, coriander, coffee, and combinations thereof. 
     
     
         20 . The method of  claim 18 , wherein the liner is at least one sheet, layer, and/or coating.