Trash removal apparatus and method

A trash removal system for separating trash and loose tobacco shreds from cigarettes that are rejected in cigarette manufacturing and packaging operations. A mixture comprising cigarettes, cigarette wrapper, trash and loose tobacco is metered onto a vibrating trash removal conveyor comprising a plurality of vertical plates arranged in a sinusoidally varying pattern.

BACKGROUND OF THE INVENTION 
The present invention relates to an apparatus and method for separating 
loose shreds of tobacco and large and small trash from rejected 
cigarettes. In the normal course of manufacturing, typically there are 
cigarettes that do not meet desired standards for product quality. For 
example, in some cigarettes, the wrapping paper might not be wrapped to a 
desireable level of firmness or there may be more or less tobacco than the 
desired amount, and hence those are not acceptable as consumer products. 
Monitoring of the manufacturing processes can result in large numbers of 
completely or partially manufactured cigarettes being rejected as 
unacceptable for these and other reasons. Rejected cigarettes typically 
are collected and removed from manufacturing areas so that cigarettes 
below the desired quality standards are not packaged, shipped or sold. 
In cigarette manufacturing operations, rejected cigarettes can comprise as 
much as 5% of the total number of cigarettes manufactured. Therefore, a 
sizeable amount of tobacco (an expensive commodity) must be destroyed 
unless the tobacco contained in the rejected cigarettes can be reclaimed. 
Reclaiming the tobacco requires that the tobacco be separated from other 
rejected cigarette constituents such as wrapping paper, filter plugs, 
filter plug wrap and cigarette cartons and other packaging materials. 
Large and small trash, such as chewing gum wrapping paper, pencils, tools, 
bolts, loose wrapper paper, loose filters, loose cartons and other 
packaging materials and other miscellaneous trash, may also become 
intermingled with rejected cigarettes from the cigarette manufacturing 
operations. Reclaiming tobacco therefore additionally requires separating 
the rejected cigarettes from a mixture also comprising large and small 
trash. Loose tobacco shreds, either from the rejected cigarettes 
themselves or other sources, also typically become intermingled with the 
rejected cigarette mixture. 
It is known to separate trash from rejected cigarettes using various 
apparatus such as conventional wire mesh screens. It is also known to use 
a separation system having parallel vertical plates, generally of the same 
height, such as Model No. BFQ1100 made by Franz Sagemuler GMBH, Nordstr. 
30 D-2935, Bockhorn, Germany. The vertical plates are arranged such that 
the top surface of each is at the same level, except that every fifth 
plate is elevated. In the Sagemuler system, loose tobacco shreds are 
screened out before the rejected cigarette mixture enters the vertical 
plate system. Large trash falls off the end and is collected in a 
container. Its typical maximum capacity is 2500 lbs. of mixture/hr. 
Operation of the Sagemuler system at higher speeds tends to result in 
cigarettes being lost due to overloading. 
DEFINITIONS 
As used herein and in the claims that follow, the following terms have the 
indicated meanings: 
"Wrapper" and "wrapping material: May include paper or other material in 
which a cigarette rod is, or may be, encased, filter plugs, filter wrap or 
tipping paper. 
"Tobacco", "filler" and "tobacco filler": May include tobacco or other 
filler material such as tobacco substitutes, stems or reconstituted 
tobacco which has been cut, shredded, extruded or otherwise prepared for 
incorporation in a tobacco product. 
"Shred": A piece of any filler. 
"Cigarette": A smoking article and its various components--which may or may 
not be intended to be burned. 
"Oven-Volatiles Content" (OV): A unit indicating the moisture content (or 
percentage of moisture) in tobacco filler. It is determined by weighing a 
sample of tobacco filler before and after exposure in a circulating air 
oven for three hours at 100.degree. C. The weight loss as a percentage of 
initial weight is the oven-volatiles content. The weight loss is 
attributable to volatiles in addition to water but OV is used 
interchangeably with moisture content and may be considered equivalent 
thereto since generally, at the test conditions, not more than about 0.9% 
of the tobacco filler weight is volatiles other than water. 
SUMMARY OF THE INVENTION 
The present invention comprises an apparatus and method for removing large 
and small trash from cigarettes that are rejected in cigarette 
manufacturing and packaging operations and for separating loose tobacco 
shreds from such rejected cigarettes. In accordance with the present 
invention, loose cigarettes with trash and loose tobacco shreds are 
metered onto a vibrating trash removal conveyor. The trash removal 
conveyor has parallel vertically oriented plates of varying heights that 
run the length of the conveyor. The vertical plates are mounted to the 
conveyor such that the top surfaces of the plates have a pattern 
comprising three or more varying heights. Preferably the pattern comprises 
sinusoidally varying heights. The vibrating action of the trash removal 
conveyor (in concert with gravity) generally causes the cigarettes and any 
small trash smaller than the distance between the plates to fall between 
the plates. Large trash, which is trash That is too large to fit between 
the plates, generally remains on top of the plates. Loose tobacco also 
falls between the plates. Below the vertical plates is a screen with a 
mesh size that is large enough to allow loose tobacco shreds to fall 
through, but small enough such that small trash and cigarettes generally 
will not fall through and will remain on top of the screen. Below the 
screen is a solid surface such that any material that falls through the 
screen is caught by the surface. 
In operation, the vibrating action of the trash removal conveyor also 
causes the materials on the conveyor (i.e. cigarettes, large and small 
trash and loose tobacco) to move along the conveyor from the first end 
where materials are placed onto the trash removal conveyor towards the 
opposite (second) end. Towards the end of the conveyor, the large trash 
falls into a receptacle, such as a vibrating pan, and is conveyed away 
from the trash removal system. Any material that has fallen through the 
screen and into the trough, primarily loose tobacco shreds, moves along 
the trough until it reaches a slot that it falls through and lands in a 
receptacle, such as a belt conveyor, and is conveyed away from the trash 
removal system. The cigarettes and loose trash move on top of the screen 
to a density separator, such as a pneumatic air leg, where the cigarettes 
are separated from the small trash. The cigarettes are conveyed away for 
further processing to remove tobacco. The small trash is conveyed away and 
discarded, recycled or reused, whichever is desired. 
The present invention may be used in conjunction with the method and 
apparatus for separating tobacco from rejected cigarettes as described in 
commonly assigned U.S. Pat. No. 4,278,100. It may also be used separately 
or in conjunction with other apparatus. 
An advantage of the present invention is that loose tobacco shreds can be 
screened out on the trash removal conveyor in conjunction with the 
vertical plate system, rather than in a separate operation before the 
rejected cigarette mixture is metered on to the vertical plates. 
A further advantage of the present invention is that large trash can be 
automatically conveyed away from the trash removal conveyor. 
A still further advantage is derived from the pattern of the vertical 
plates and the simultaneous screening and collection of large trash is 
that rejected cigarette containing mixtures can be processed at higher 
speeds than was possible with prior trash removal conveyors. Speeds as 
high as 6000 lbs. of mixture/hr. are possible. In addition, at comparable 
speeds, a more thorough separation of components is achieved. An advantage 
of operating at higher speeds is that the trash removal conveyor can be 
integrated with other high speed apparatus, such as high speed ripper 
systems. 
It is an object of the present invention to provide a reliable and 
effective way of separating large and small trash from the loose rejected 
cigarettes. 
It is a further object of the present invention to provide a reliable and 
effective way of collecting loose tobacco shreds that are intermingled 
with large and small trash or rejected cigarettes. 
It is yet a further object of the present invention to provide a vibrating 
trash removal conveyor that processes cigarette containing mixtures at 
high 
speeds, such as over 2500 lbs. of mixture/hr.

DETAILED DESCRIPTION OF THE INVENTION 
The various components of a rejected cigarette mixture 10 containing any 
combination of large trash, small trash, loose tobacco shreds and rejected 
cigarettes are separated by metering the mixture 10 onto a vibrating trash 
removal conveyor 20, which separates the components. 
In a typical cigarette manufacturing facility, the composition of the 
mixture 10 will vary from batch-to-batch or from cigarette 
maker-to-cigarette maker, depending on the nature of the rejected 
cigarette flow and the composition of the extraneous trash that gets mixed 
in with the collection of rejected cigarettes from the cigarette 
manufacturing areas. In the present invention, the mixture may contain any 
proportion of each of the components (i.e. large and small trash, loose 
tobacco and cigarettes). 
The mixture 10 may be metered onto the trash removal conveyor. 20 using any 
means, including without limitation funnels, vibrating conveyors, 
transport belts and shovels. In the embodiment depicted in FIG. 1, the 
mixture is collected from the cigarette makers and transferred to a 
storage bin 30. The mixture 10 is then transferred by an inclined conveyor 
belt 40 to a metering apparatus 50. Any type of metering apparatus may be 
used. As shown in FIG. 1, the mixture 10 can be fed from the inclined 
conveyor belt 40 to a hopper 60. 
Since the trash removal system of the present invention may be used in 
conjunction with ripper operations or other tobacco and cigarette 
processing operations, it may be desired (for the benefit of those other 
operations) to raise the moisture content of the mixture 10 from the 12.5% 
OV that is common in rejected cigarette tobacco. Moisture may be injected 
into the mixture in order to raise the moisture content. In a preferred 
embodiment, the hopper 60 feeds the mixture 10 into a steam tube chamber 
70. Steam is injected into the mixture 10 in the steam tube chamber 70 in 
order to raise the moisture level of the mixture 10 to a desired level. 
Preferably, a level of 13.5%-14.5% OV is attained although other OV levels 
may be used. 
The amount of moisture absorbed by the mixture 10 may be regulated by 
adjusting the amount of time in which the mixture is in the steam tube 
chamber 70 and the steam pressure. As steam pressure increases, the amount 
of moisture absorbed also increases. Likewise, as the amount of time 
increases, the moisture level typically increases. One way to adjust the 
amount of time in which the mixture 10 remains in the steam tube chamber 
70 is to control the height of the mixture present in the steam tube 
chamber 70 (as measured from the bottom 80 of the steam tube chamber). One 
way to control the height of the mixture is to use a control mechanism 
that senses the height using a vertical array of photo-electric cells 90; 
then, when &he height is too low, the rate at which the inclined feeder 
belt 40 feeds mixture 10 into the hopper 60 is increased; and, conversely, 
when the height is too high, the rate at which the inclined feeder belt 40 
feeds mixture 10 into the hopper 60 is decreased. It also has been 
observed that if the height of the mixture is too low, condensation can 
occur on the walls of the steam tube chamber and the mixture can get wet. 
In addition to the components described above, the metering apparatus 50 
shown in FIG. 1 contains a metering belt 100 and a feeder belt 110. 
Preferably, the speed of the metering belt 100 can be adjusted in order to 
control the rate at which the mixture 10 is fed onto the feeder belt 110 
and the trash removal conveyor 20. The feeder belt transports the metered 
mixture 10 to the trash removal conveyor 20. Other means of conveyance 
also may be used to perform the functions of the metering belt 100 and the 
feeder belt 110, such as vibrating conveyors or hand conveyors such as 
barrels or trucks. 
Preferably a metal removal system 120 operates to remove metallic objects 
that are in the mixture 10 before the mixture is fed onto the trash 
removal conveyor 20. 
The metal removal system may be located anywhere in the metering apparatus. 
In the preferred embodiment, it is located near the end of the feeder belt 
110. Although metallic objects can be removed manually, it is preferred 
that a magnet be used. One drawback of using a magnet is that it will only 
remove ferrous objects. However, it is generally more economical to use a 
magnet. 
As shown in FIGS. 1-5, the trash removal conveyor of the present invention 
generally has a number of parallel vertically oriented plates 130 
separated by spaces of a predetermined width, a screen 140 below the 
plates, a surface 150 for collecting materials that fall through the 
screen, a receptacle 160 for collecting large trash, another receptacle 
170 for collecting and conveying material from surface 150, a density 
separator 180, and a means 190 for vibrating the trash removal conveyor 
20. 
In operation, the mixture 10 is metered onto the trash removal conveyor 20, 
which is vibrating. The vibrating means 190 causes the trash removal 
conveyor 20 to vibrate. The vibrating action causes materials on the 
conveyor (including any of its parts), including the components of the 
mixture 10, to move along the trash removal conveyor from the first end 
where the mixture 10 is metered onto the conveyor towards the opposite 
end. 
The operation of vibrating conveyors is widely known. Any vibrating means 
may be used, including any of the widely used means. In the preferred 
embodiment, the vibrating means 190 causes the trash removal conveyor 20 
to move in a concentric motion with a 7/8 in. stroke. This causes the 
mixture 10 and its components to move along the conveyor at approximately 
60 ft./min. 
The plates 130 are vertically oriented and may be held in place by any 
means, such as mounting rods 200 that pass through each plate and are 
attached to at least one of the two sidewalls 210, 220 of the trash 
removal conveyor. The mounting rods 200 may be attached to the sidewalls 
210, 220 by any means, as long as they cannot move vertically. Slippage, 
such as in the horizontal or axial directions, may be tolerated, but 
preferably the mounting rods 200 are immovably attached to the sidewalls 
210, 220. 
The top surfaces of the plates 130 are arranged in a predetermined pattern 
to promote separation of the various components of the mixture 10. It has 
been determined that a sinusoidal arrangement, as depicted in FIGS. 3, 5 
and 6, achieves the best results. In such an arrangement, there are three 
or more levels at which the top surfaces of the plates 130 are set. They 
are arranged such that a plate with its top surface being at the highest 
level has next to it at least one plate with a lower top surface, with a 
space in-between. The top surfaces of the next plates are succeedingly 
lower until a plate with its top surface at the lowest level is reached. 
Then the top surfaces get higher until a plate with its top surface being 
at the highest level is reached. This pattern is repeated until the area 
between the two side walls 210, 220 of the trash removal conveyor is 
populated with plates 130 and spaces between the plates. FIGS. 3 and 5 
depict the preferred embodiment in which there is a sinusoidal arrangement 
of plates 130 having three top surface levels. FIG. 6 shows an alternative 
embodiment in which there is a sinusoidal arrangement of plates 130 having 
four top surface levels. Other arrangements of plates 130 in which the 
plates have various levels also may be used. 
The screen 140 is located below the plates 130. In operation, the screen 
140 functions to separate loose tobacco from the mixture 10. The mesh size 
of the screen therefore may be any size that is large enough to allow 
loose tobacco shreds to pass through. As the mesh size selected increases, 
the likelihood that all loose tobacco shreds will be able to pass through 
increases. However, as the mesh size increases, the likelihood that some 
small trash, such as loose filters and cigarette paper can pass through 
also increases. Preferably, the mesh size also is sufficiently small such 
that most small trash, such as loose filters and cigarette wrapper, cannot 
pass through In the preferred embodiment, a 31/2 mesh per linear inch 
screen is used. 
A surface 150, such as a trough, is located below the screen 140 such that 
any material that passes through the screen is retained on the surface 
150. The surface 150 is constructed such that the material that passes 
through the screen 140 does not adhere to the surface 150. In operation, 
it is desired that material on the surface the caused by the vibrating 
action of the trash removal conveyor to move along the surface 150 from 
the first end (where the mixture 10 is metered onto the trash removal 
conveyor) towards the opposite (second) end. 
A receptacle 170 is located such that material that is conveyed along the 
surface 150 falls into the receptacle 170. In operation, the material that 
has fallen through the screen, primarily loose tobacco shreds, moves along 
the surface 150 until it reaches a slot in the surface 150, which it falls 
through. The material then may be collected from the receptacle 170 by any 
means and transferred for further processing. In one embodiment, the 
receptacle 170 is a trough having vertical side walls and a belt conveyor 
as its bottom surface. In a preferred embodiment, the receptacle 170 is a 
trough having an angled bottom surface 172 and a front wall 174 and a rear 
wall 176. The front and rear walls 174, 176 may be vertical or angled. In 
this preferred embodiment the material that falls through the slot and 
into the trough 170 is caused by the vibrations of the trash removal 
conveyor to be conveyed in the direction of the angled bottom surface 172. 
Large trash, which is defined as trash that is too large to fit between the 
vertical plates 130, is collected in a large trash receptacle 160. In 
operation, the large trash is conveyed along the top surfaces of the 
plates 130 until it reaches the large trash receptacle 160. The large 
trash then may be collected from the receptacle 160 by any means and 
transferred for further processing or for disposal as waste. In one 
embodiment, the receptacle 160 is a pan having vertical side walls and a 
belt conveyor as its bottom surface. In a preferred embodiment, the 
receptacle 160 is a pan having an angled bottom surface 162 and a front 
wall 164 and a rear wall 166. In this preferred embodiment the large trash 
in the pan 160 is caused by the vibrations of the trash removal conveyor 
to be conveyed in the direction of the angled bottom surface 162. 
A density separator 180 is located at the second end of the trash removal 
conveyor. In operation, materials in the mixture 10 that are small enough 
to fall between the plates 130, but are too large to pass through the 
screen 140, are conveyed along the top surface of the screen 140 from the 
first end to the density separator. Generally, these materials that are 
conveyed into the density separator 180 are rejected cigarettes and small 
trash including, inter alia pieces of loose wrapper and filters. 
Generally, the rejected cigarettes have a higher density than the other 
materials. The density separator 180 separates the rejected cigarettes 
from the other material. In the preferred embodiment, the density 
separator is a pneumatic air leg. In such a pneumatic air leg, an air 
stream is directed upwards; material enters into the air stream; materials 
with a higher density tend to fall downwards if the force of gravity is 
greater than the upward force caused by the drag created by the airstream; 
and materials with a lower density rise in the direction of the airstream 
if the force of gravity is less than the drag created by the airstream. In 
operation, the cigarettes fall downwards and are collected and transferred 
for further processing. The small trash, such as wrapper paper and filter 
plug wrap filters, rises with the airstream and is collected for further 
processing (such as recycling or further separation) or disposal. In a 
preferred embodiment, the airstream velocity is at least 300 ft./min.