Abstract:
The present invention relates to a biodegradable dual density cigarette. The invention provides for a cost-effective process that ensures that the non-filter cigarette has smoke delivery quality comparable to that of a conventional filter cigarette. The invention also substantially reduces the tar and nicotine contents. The dual density cigarette is biodegradable and therefore environment friendly.

Description:
FIELD OF THE INVENTION  
         [0001]    The present invention relates to biodegradable dual density filter cigarette.  
           [0002]    More specifically the subject invention relates to biodegradable dual density filter cigarette comprising of two portions, a tobacco rod and butt portion joined to each other longitudinally.  
           [0003]    The embodiment of the invention resides in the cost effective process of manufacturing the dual density cigarettes and subsequent product such as high density cigarettes, plugs and other combinations.  
         PRIOR ART  
         [0004]    The cigarettes presently available in the national and International market can be categorized in two classes namely, plain (non-filter) and filter cigarettes. Cigarettes are made in various sizes in diameter and lengths. The cost of Plain cigarettes is substantially lower. These “plain cigarettes” attract smokers of two types—“Bidi smokers wanting to upgrade themselves” and “filter cigarette smoker opting for low cost cigarettes”.  
           [0005]    The non-filter cigarettes have tobacco with normal density throughout the length of the cigarette. Often the loose tobacco particles enter the mouth of the smoker due to the absence of a filter. The Non-filter cigarette often turns soggy at the smoking end due to constant contact with the smoker&#39;s mouth. Besides, due to the relatively loose packing density of the tobacco and loss of tobacco particles from the nonsmoking end, the cigarette loses its stiffness.  
           [0006]    Filter cigarettes contain tobacco of normal density along with synthetic filters. The filter plug in a filter cigarette comprises of fibrous material attached to a normal density tobacco rod. The fibrous material can be cellulose, acetate tow, polypropylene tow, or any of the other known kind of synthetic fibrous material. These filter cigarettes are non-biodegradable, and require special cigarette making equipment and additionally these cigarettes are more expensive than non-filter cigarette.  
           [0007]    U.S. patent application Ser. No 09/988,828 teaches about a filter cigarette with tobacco filter in which the tobacco strand enclosed by a cigarette paper. The tobacco used is manufactured without using medium cut roll stem and without reconstituted tobacco with a width cut of 0.3 to 0.6 mm and the filter has a tobacco packing density of 350 to 400 g/cm 3 .  
           [0008]    EP 1250 854 A1 describes a poison-reduced cigarette includes adding hydrate of double salt of ferroso-ferric chloride into tobacco and cigarette filter to react with nicotine to form salt which will not be absorbed by the mucous membranes in the smoker&#39;s respiratory system for minimizing nicotine poison and for enhancing the smoker&#39;s health.  
           [0009]    EP 1032282 describes a filter for tobacco products, in particular cigarettes, is made of a cellulose nonwoven fabric produced by an air-laid process and spirally rolled.  
           [0010]    EP 1032283 describes a filter cigarette comprising a biodegradable filter and a tobacco strand surrounded by cigarette paper, a non-woven air-aid cellulose filter with a normal retention capacity and a filter ventilation area extending in a peripheral direction. The filter cigarette has the combination of features. The filter has a condensate retention capacity of 40-60%; the non-woven cellulose is non-crimped, the nicotine/tobacco strand condensate yield ratio lies between 0,6 and 0,9 (nicotine *10/condensate), the apparent density of the tobacco mixture of the tobacco strand ranges from 200 to 250 mg/ml, the tobacco strand drag is between 45 and 65 mmw WS when measured in an enclosed form, air permeability of the cigarette paper is 20-50 CORESTA units and the filter ventilation degree is 15-50%.  
           [0011]    WO 01/58290 A1 discloses a cigarette filter for easily removing harmful materials like nicotine and tar from cigarette smoke. During inhalation, the filter can filter harmful ingredients such as nicotine and tar included in cigarette smoke, through a front filter, a mugwort-impregnated filtering-net, a diffusing body, a pine resin-impregnated filtering-net and then a back filter. Additionally, the filter which incorporates the mugwort and the pine resin therein thus is helpful in preserving the health of the smoker, as well as allowing the smoker to feel normal during inhalation, which results from the aromatic properties of the mugwort and the pine resin impregnated into filtering-nets present within the filter.  
           [0012]    The filters of cigarettes designed to filter harmful materials, such as nicotine and tar, are provided at one end of the cigarette. Such filters are typically classified into several types as follows: That is, the conventional filters of the cigarettes are classified according to their structure into a single filter consisting of one integrated filter, a double filter formed by a linear arrangement of two filter segments, and a multiple filter formed by the linear arrangement of a plurality of different kinds of filter segments. The filters are also classified according to the material of the filters into a fiber filter, a chemical granule-laden filter, and a carbon granule-laden filter. In the prior art, fiber filters allow hazardous materials included in the cigarette smoke to simply pass through their fibrous matrix, and thus a large effect cannot ba expected. However, fiber filters, particularly those laden with carbon or chemical granules for removing nicotine and tar, have been most preferably and widely used as filters for cigarettes.  
           [0013]    Conventionally a cigarette rod making machine employs a distributor which delivers fragmentized particles of tobacco leaves, fragmentized sheets of reconstituted tobacco and/or fragments of artificial tobacco to a stream building zone wherein the particles from a continuous stream. Such stream contains surplus of fibrous material and is converted into a continuous rod during travel with a conveyor past a trimming or equalizing device which removes the surplus. The resulting rod (also called filler) is thereupon condensed and draped into a web of cigarette paper or other suitable wrapping material to form with the web a cigarette rod which is subdivided (e.g., by a conventional cutoff) into sections of unit length or multiple unit length. Thus obtained cigarettes are delivered to storage, to a packing machine or to a filter tipping machine. Certain types of filter rod sections are or can be produced in a similar manner except that the fibrous material which forms the stream is a substance which intercepts certain presumably harmful ingredients of tobacco smoke when it constitutes the rod-shaped component of the filter mouthpiece in filter cigarette.  
           [0014]    The object of the present invention is to provide the smoker a filter cigarette having a filter portion which is biodegradable that substantially reduces the tar and nicotine elements and having higher chloride contents.  
           [0015]    The object of the present invention is to provide the smoker a filter cigarette which is at the same time inexpensive and environment friendly.  
           [0016]    Yet another object of the present invention is to provide a naturally biodegradable cigarette having a smoke delivery profile comparable to the synthetic filter cigarette.  
           [0017]    Another object of the present invention is to provide a cost-effective process of producing dual density tobacco rod and subsequent product usage option such as high-density cigarette, plugs and other combinations.  
           [0018]    Further object of the present invention is to give satisfaction comparable to that of the conventional filter cigarette without actually having synthetic filter in the cigarette.  
           [0019]    The present invention provides a biodegradable, environmental friendly, cost effective filter cigarette with reduced health hazards.  
         SUMMARY OF THE INVENTION  
         [0020]    Accordingly the present invention relates to a biodegradable dual-density cigarette comprising of a rod of tobacco of predetermined length wrapped in cigarette paper wherein the tobacco content are packed at high density at the butt end of a predetermined length and normal density for the remaining length upto the smoking end.  
           [0021]    The tobacco content at the said high density end primarily includes mixtures of cut and rolled stem (CRS), but can also include mixtures of graded tobacco, reconstituted tobacco, dust with binders or natural materials.  
           [0022]    The normal density of such rod is in the range of 225 mg/cc to 280 mg/cc while the high density of such rod is at least 280 mg/cc  
           [0023]    The length ratio of normal and high density of said tobacco rod is 5:1 and is configured so as to maintain the desired smoke delivery profile. The high-density end of the said cigarette is wrapped with porus paper of a different colour for the identification of the butt end of the cigarette by the user.  
           [0024]    Accordingly the present invention relates to a biodegradable dual density cigarette comprising a filler or tobacco rod and butt portion joined to each other longitudinally in a ratio of 5:1 wherein the tobacco rod is a blend of tobacco wrapped in a cigarette paper at a pressure drop of 22 to 50 mm of water column, the butt portion comprising at least cut-roll stem particles of expanded fibres of density of at least 0.28/cc wrapped in a porous paper of at least 100 mm of water gauge.  
           [0025]    Accordingly the present invention also relates to a process for manufacturing of biodegradable dual densities cigarette comprising the steps of:  
           [0026]    subjecting the stem of the tobacco leaf to a conventional conditioning process for 10 to 20 minutes at 30-40° C. to quench the moisture uniformly;  
           [0027]    passing the said quenched stem through conditioning tunnel or through a flattner or a roller to flatten the stem;  
           [0028]    cutting the stem into small particles of the size 30 to 180 cpi;  
           [0029]    cutting the small particles through an expansion heated tunnel at a temperature of 100 to 103° C. for a period of 20 to 30 seconds;  
           [0030]    passing the said particles through a drier and a classifier to obtain a cut roll stem (CRS);  
           [0031]    cooling the CRS at room temperature by storing in boxes rolled humidifier;  
           [0032]    encapsulating the cooled cut rolled stem in a filter wrapping paper to obtain the filter butt;  
           [0033]    processing the filler or tobacco end with tobacco in the conventional manner;  
           [0034]    joining the butt portion in the conventional manner to obtain the biodegradable filler cigarette.  
           [0035]    The subject invention can better be understood with reference to the accompanying drawings. However, the same are for illustrative purposes and should not be construed to restrict the scope of the invention. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0036]    [0036]FIG. 1 illustrates a dual density cigarette having normal density tobacco at one end and high-density tobacco at other end. The length ratio of normal and high density can be configured so to maintain the expected smoke delivery profile. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0037]    The present invention provides for enhancement of smoke delivery profile comparable to normal synthetic filter cigarette as well as results in substantial lo reduction of tar and nicotine. Due to the high density tobacco at the mouth end the sogginess of tobacco when put into the mouth and the entrance of loose tobacco particles entering into the mouth is also avoided  
         [0038]    The cigarette is 100% biodegradable and is cost effective since the conventional machines can be used.  
         [0039]    This cigarette is to be smoked through high-density end and this high density tobacco portion is tipped with porous cork tipping paper of different colour for identification to enable the consumer to know that tipped portion of the cigarette is to be put in the mouth.  
         [0040]    High-density tobacco rods can be manufactured using tobacco material such as cut and rolled stem, graded tobacco, reconstituted tobacco, tobacco dust with binders as well as various combination of above or natural materials.  
         [0041]    Density of such rod may be selected as per individual product need. Normally the density selected are at least 280 mg/cc. FIG. 1 shows that the tobacco or filler rod ( 1 ) is a blend of tobacco wrapped in a cigarette paper at a pressure drop of 22 to 50 mm of water column. The filler rod ( 1 ) is filled with blend of tobacco comprising 75 to 85% of lamina and 15 to 25% of the expanded stem fibres or cut-roll stem. The lamina is normal density tobacco of 4-6 cc/gm at the rate of 12.5% oven volatile preferably 5-6 cc/gm at the rate of 12.5% oven volatile. The butt portion ( 2 ) comprising cut-roll stem particles of expanded fibres of the density of at least 0.28/cc wrapped in a porous paper of at least 100 mm of water gauge. The expanded stem is 4-7 cc/gm at the rate of 12.5% oven volatile, preferably 6-7 cc/gm at the rate of 12.5% oven volatile. The pressure drop in the tobacco rod is 5-9 water column per mm. of filler end while the pressure drop in the butt end is 3-4 water column per mm. The stem portion is the mid rib of tobacco plant leaf having lower nicotinic content and higher chloride content.  
         [0042]    Normal and high-density tobacco rods are manufactured on cigarette making machine using normal cigarette paper as wrapper for the rod. The stem of the tobacco leaf is subjected to a conventional conditioning process for 10 to 20 minutes at 30-40° C. to quench the moisture uniformly. The quenched stem is passed through conditioning tunnel or through a flattner or a roller to flatten the stem. The stem is then cut into small particles of the size 30 to 180 cpi. The small particles are cut through an expansion heated tunnel at a temperature of 100 to 103° C. for a period of 20 to 30 seconds. The particles are passed through a drier and a classifier to obtain a cut roll stem (CRS). The CRS are cooled at room temperature by storing in boxes rolled humidifier. The cooled cut rolled stem are encapsulated in a filter wrapping paper to obtain the filter butt;.  
         [0043]    The filler or tobacco rods are made to required length and then supplied to assembler, the purpose of this unit to assemble the normal and high density tobacco filter butts in the ratio of 5:1.  
         [0044]    The assembler further cuts the high-density rods in suitable pieces normally 4 to 6 pieces called “Plugs” but other combination are also possible. This is followed by assembly of these “plugs” with the normal tobacco rod and over tipping with the tipping paper of suitable width, size and colour. The tipping paper or plug wrap can either be normal or relatively high porous to give required smoke delivery values.  
         [0045]    This specially made dual density cigarette is capable of delivery of smoke profile comparable to any other conventional filters as is evident from the test results.  
         [0046]    While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in art that various other changes and modifications can be made without departing from the sprit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are with in the scope of the invention.  
         [0047]    The following table shows the typical example of the property of the butt end:  
                                                                             AVERAGE   MINIMUM   MAXIMUM                                        MOISTURE   10.03   9.10   10.80           NICOTINE   0.73   0.22   1.34           TRS   10.87   2.61   20.21           CHLORIDE   2.70   1.28   3.59                      
 
         [0048]    The following table shows the property of the filler or tobacco rod:  
                                                                             AVERAGE   MINIMUM   MAXIMUM                                        MOISTURE   11.79   11.00   12.50           NICOTINE   1.82   1.63   2.00           TRS   14.60   12.15   17.12           CHLORIDE   0.72   0.49   0.96                      
 
         [0049]    It is clear that the moisture nicotinic content are less in the butt end while TRS and chloride content are more in the but end as compared to the filler end.  
         [0050]    Analytical Tests  
         [0051]    A number of analytical tests were conducted to compare the tar and nicotine content of the non-filter cigarettes, filter cigarettes and dual density cigarettes. The three analytical tables are as given below:  
         [0052]    Table 1 comprises of 3 sub-tables showing the density trend of micro plain cigarettes (Table 1A), Plain and regular filter type cigarettes (Table 1B) and King Size Brands (Table 1C).  
         [0053]    The Tables 1A, 1B and 1C show the comparative tobacco density that exists in different brands of cigarette having a standard length of 59 mm. The data is taken for two years i.e. for the years 2000 and 2001. the figures show that the average density of tobacco in micro plain brands (Table 1A), filter size brands (Table 1B) and the king size brands (Table 1C) ranges between 232 mg/cc and 264 mg/cc.  
         [0054]    The Table 2 features the analytical data showing the comparison of Tar and Nicotine in the non-filter and dual density cigarettes. The analytical data reveals that the Dual Density Cigarettes shows lesser value of the tar &amp; nicotine as compared with the non-filter cigarettes of same lengths.  
         [0055]    Table 3 shows the comparison of “tar” and “nicotine” yield obtained from the conventional filter tipped cigarettes, the dual density cigarettes fitted with present invention and the non-filter plain cigarette. The table reveals that the quality of smoke delivery of dual density cigarette is comparable with the filter cigarette. The tar content of the smoke from the dual density cigarette with a circumference of 24.44 mm is slightly higher than the tar content in the filter cigarette with the circumference of 24.46 mm.  
                                                                                                                                                                     TABLE 1A                           DENSITY TREND OF MICRO PLAIN BRANDS            BRANDS           59 mm   Month            Brands   Year   JAN   FEB   MAR   APR   MAY   JUN   JUL   AUG   SEP   OCT   NOV   DEC   AVG   MIN   MAX                    Cav Super   2001   259               261   254   253           251   252       256   244   266           2000   256   259       257   250   251   266   254   244       260       FS Super   2001               245   272   257   252   255   250   258   250   250   254   245   272           2000                               250   256       RW Super   2001   255       254   264   260   246   253   233   249   248   255   271   253   233   278           2000   258   241   254   278   251   266   262   243   245   245   247   242       Bristol Std   2001       274                           271           246   264   246   274           2000       Capstan   2001                       246                       233   240   233   246       Super           2000       SCISSORS   2001                       268           260               258   247   268       STANDARD           2000       247                  
 
         [0056]    [0056]                                                                                                                                                                     TABLE 1B                           DENSITY TREND OF PLAIN &amp; REGULAR FILTER SIZE BRANDS                Month            BRANDS   Year   JAN   FEB   MAR   APR   MAY   JUN   JUL   AUG   SEP   OCT   NOV   DEC   AVG   MIN   MAX                    CVGL - 69 mm   2001       261   267       253   257   260   267   255   263   263   263   260   247   267           2000   263   247   265   257   261               250   261   265       RW Plain -   2001           270   273           245   272       249   249   251   252   242   273       67 mm           2000   245   243   247   244   251   245   253   255   255       244   242       Scissors   2001   245   248               238                   247       245   238   248       Plain - 68 mm           2000       FS Special   2001   254   259   254   257   255   263   267   278   262   260   262   266   260   254   278           2000   254   255   254   257   255   262   255   267   264   255   270   258       FS Premier   2001   260   260   257   259   256   258   256   271   260   261   264   262   260   249   271           2000       254       261   257   260   249   265   257   264   267   252       RW Flake   2001   257   253   254   261   261   265   265       266   252   258   267   258   244   267           2000   251   255   244   258   255   264   250   255   265   257   265   263       GF Premium   2001       250   263   254       254   255           256   261   257   258   250   266           2000       256       263   266       261   257           262       Wills Flake   2001           256           255   262               265       261   255   274           2000               256           264   274           256                    
         [0057]    [0057]                                                                                                                                                                     TABLE 1C                           DENSITY TREND OF KING SIZE BRANDS                Month            BRANDS   Year   JAN   FEB   MAR   APR   MAY   JUN   JUL   AUG   SEP   OCT   NOV   DEC   AVG   MIN   MAX                    FS Kings   2001   248   246   242   255   251   251   255   266   257   253   252   255   252   242   266           2000   250   247   254   248   246   252   255   255   257   249   257   248       GF Kings   2001       251   249   247       249   249           253       260   251   244   264           2000       252   257       252   244   244   248           251       Classic Kings   2001       264               244           252               249   244   255           2000       247       255               244           251       BH Sp   2001               242       233           236               242   233   249           2000           249                   246           245       555 Kings   2001                                   244               244   243   245           2000               243                           245       Marlboro   2001               225       233           235               232   225   235       Lights   2000       235                    
         [0058]    [0058]                                                                                                                                                                       TABLE 2                       14.2.2002 ANALYTICAL REPORT                                        DUAL DENSITY       CIGT.   PLAIN   59 × 24.50 × 11 mm CRS (DEN.            Sample Type       59 × 24.50 PL (DEN. 262 MG/CC   262 MG/CC)            TEST   59 MM   1   2   3   4   AVG   1   2   AVG               ISO Tar   MG/CIG   16.9   17.4   16.3   15.9   16.6   15.5   15.2   15.4       Nicotine   MG/CIG   1.43   1.57   1.47   1.48   1.49   1.26   1.27   1.27       Cigt. Length   MM   59   59   59   59   59   59   59   59       Ft Length/type   MM   —   —   —   —   —   11/CRS   11/CRS   11/CRS       Circumference   MM   24.57   24.57   24.57       24.57   24.44   24.43   24.44       Density a   MG/CC   259   261   263       261   259   263   261       12.5% O.V.                            DUAL DENSITY       CIGT.   PLAIN   69 × 24.50 × 11 mm CRS (DEN. 262            Sample Type       69 × 24.50 PL (DEN. 262 MG/CC   MG/CC)            TEST   69 MM   1   2   3   4   AVG   1   2   3   AVG               ISO Tar   MG/CIG   21.2   19.8   22.1   21.1   21.1   19.9   20.1   19.8   19.9       Nicotine   MG/CIG   1.81   1.88   1.85   1.87   1.85   1.68   1.62   1.59   1.63       Cigt. Length   MM   69   69   69   69   69   69   69   69   69       Ft. Length/type   MM   —   —   —   —   —   11/CR   11/CR   11/CR   11/CR                                   S   S   S   S       Circumference   MM   24.59   24.59   24.58       24.59   24.42   24.42       24.42       Density a   MG/CC   262   262   268       264   269   264       267       12.5% O.V.                    
         [0059]    [0059]                                                         TABLE 3                                   Smoke       69 × 24.5 × 11   59 × 24.5 × 11           parameters   59 × 24.5 PI.   mm CRS   mm CA                                        ISO Tar   16.6   15.4   14.9           Nicotine   1.49   1.27   1.27           Circum-   24.57   24.44   24.46           ference