DESC:Field of invention

The present invention relates to filler for use in smoking tobacco product. Particularly, the present invention relates to the utilization of tobacco that is in a physical state, which otherwise cannot be used as a part of tobacco blend in smoking article. More particularly the present invention relates to a composition and process for manufacture of reconstituted tobacco sheet, constituted by tobacco remains and/or processed tobacco to use as filler along with tobacco blend in a smoking article.

Background and prior art of the invention
Tobacco, after harvesting, passes to through several cycles of cutting, processing, packing, further cutting into shreds and mixing with other grades to finally use in smoking article in the form of blend. During the process significant amount of tobacco is left over in the physical state that otherwise can not be used. The conversion of tobacco remains into form, which can be used, is called as reconstituted tobacco. Once prepared the reconstituted tobacco may be cut into shreds to produce tobacco filler, which can be used along with cut tobacco blend. In modern tobacco industry, the reconstituted tobacco is recognized as an essential ingredient due to its value addition. There have been certain efforts done in the past to utilize the tobacco remains in proper way.
IN 165620 mentioned dry forming reconstituted tobacco using lamina, stem and fines along with cellulose fibers. The mixture is conveyed by an airstream and forming was made on a moving wire assisted with a vacuum. The web thus formed is sprayed with a solution of binder followed by drying and cutting. The raw materials used for making reconstituted sheet required additional fibrization process to increase the fiber content. The method described in IN’620 include additional processes such as fibrization of raw material at controlled moisture. Further during process certain amount of fines could not be utilized and has to be recycled again. Therefore the process could not use tobacco fines effectively.
IN 181192 describes the reconstituted tobacco sheet with improved quality and survivability due to an optimization of the tobacco mean particle size and a reduction in the air content of the slurry. The invention uses the tobacco, gum, preserving agent and flavor. The invention required a particular size of particle and is not able to use tobacco fines effectively. Further very high quantity of tobacco with starch based gum as binder is expected to yield a reconstituted sheet with poor physical properties and consequently would be difficult to process further to make it cut and blend with tobacco blend during cigarette manufacturing.

IN 194046 uses the paper making process to convert tobacco dust into reconstituted tobacco sheet with much reduced percentage of nicotine, sugars and chloride. The invention uses jute and bamboo to obtain pulp and using the said pulp, mixed with tobacco dust and carboxymethyl cellulose in recon making. This process generally required softening of tobacco waste by means of cooking followed by filtration. It is very obvious that due to filtration the essential components of tobacco will also be filtered leaving behind a sort of neutral filler and further the process is very lengthy. Therefore this invention yields in reconstituted tobacco sheet with very less characteristics of tobacco remained in it.
IN 204309 described the method of handling an extruded reconstituted tobacco filament downstream of die means through which the filament is being extruded. The invention is more related towards pneumatic conveyance means comprising in combination of gaseous medium transfer means and duct mean.
IN 246069 mentioned a reconstituted tobacco sheet for use in a cigarette, includes tobacco, wood pulp, binder, humectant and flavor and the use of such reconstituted tobacco to modify the burn rate of cigarette. The invention describes a process for making such sheet by paper making process, which involves the separation of water-soluble compounds and solid portion followed by adding back to reconstituted sheet. Such process loses out the typical characteristics of tobacco. Further, using high quantities of non-tobacco ingredients impart undesirable taste characteristics to the cigarette and deteriorating product characteristics.
IN 240732 mentioned a process of making reconstituted tobacco using tobacco, wood pulp, binder and flavoring compound. The patent also mentioned a smoking article, having such reconstituted tobacco split inner wrap strips extent coaxially along the tobacco column between the inner surface of an outer wrap and the tobacco column, would exhibit burn rate modification. It is known that double wrapping of smoking article would lead to reduce in burn rate.
US 7856988 mentioned a process of manufacturing a reconstituted tobacco material, including preparing a heated mixture of water and sugar, providing a liquid flavorant, mixing tobacco particles with water and gum binder and casting or extruding the reconstituted tobacco mixture into reconstituted tobacco materials, which can further be shredded into desired size. The invention is more particularly related to retention of menthol in reconstituted tobacco sheet. Moreover, the usage of additional sugar would lead to the formation of several undesired constituents during cigarette burning.

US 5562108 described a tobacco reconstitution process, wherein a mixture comprising particulate tobacco, starch and binder with the addition of carbonated or bicarbonated water is extruded to provide a web form extrudate. It is difficult to regulate the strength, elasticity and burn characters of such reconstituted sheet.
US2008216854 discloses a reconstituted tobacco sheet having a high content of aerosol former which is manufactured by preparing an aqueous slurry containing a tobacco material which is formed into a sheet. The moisture content of the sheet can be reduced to less than about 50% by weight before incorporating an aerosol former such as glycerin, which can be at a temperature below about 40°C., followed by drying the sheet. The sheet can be trashed, blended with natural tobacco strips, and shredded into a cut filler of a smoking article. US’854 mentions that the tobacco materials can be tobacco leaf scraps, tobacco stems, tobacco dust created during tobacco processing, and/or tobacco leaf prime lamina strip. For example, the tobacco material can contain at least about 50% by weight stems, preferably about 70-80% by weight stems, with the balance containing tobacco leaf scraps and/or tobacco dust. Tobacco materials can include other additives, such as wood cellulose fibers to improve the strength of the reconstituted tobacco sheet and allowing for lower stem content. However the intermediate step i.e. reducing the moisture and then adding the aerosol former, as described in US’854 makes the process further lengthy. Further removal of soluble portion from the slurry would reduce the typical tobacco characteristics significantly. The process mentioned is more towards like paper making process, which is very expansive and attracts huge investments.
Hence, there is a need in the art to design a formulation that provides the best utilization of tobacco remains by making reconstituted tobacco in a way that regulates the burn rate of a smoking article. Such reconstituted tobacco with burn rate modifiers can be used along with the tobacco blend itself and not on the cigarette wrapper. Further, there is a need to provide a reconstituted tobacco, which results in desired use of tobacco remains with retention of tobacco characteristics and regulated burn rate.
Most of the prior art teaches the addition of burn modifiers on the cigarette paper. It is very obvious to a person skilled in the art to use double layered wrappings. Moreover, it may affect the characteristics of the product and involves manufacturing complexities. For instance to add strips of additional sheets underneath the cigarette wrapper is considered as disadvantageous.

As mentioned above, all the available methods of manufacture reconstituted tobacco sheet require high amount of non-tobacco material, which produces undesired characteristics on burning. Further the main processes mentioned in prior art would require separation of water-soluble materials from tobacco and adding back to the solid portion after/during processing. Such process leads to reduction in the typical characteristics of tobacco in the reconstituted sheet.
Moreover the reconstituted tobacco might have its own burn rate and it is challenging to modify its burn rate to be used in the conventional smoking article. Further, there is no teaching in the prior art for a reconstituted tobacco sheet, which provides the controlled burn rate in a way favorable to overall burning of smoking article.
Additionally, there is no reconstituted tobacco product, which provides effective use of tobacco remains in cost effective manner.
The present invention further offers the best utilization of tobacco remains and thereby provides cost benefits.

Objects of the invention
It is an object of the present invention to overcome the drawback of the prior arts.
It is another object of the present invention to provide a composition comprising reconstituted tobacco sheet and shreds.
It is another object of the present invention to provide a novel composition for reconstituted tobacco and the process for making the same.
It is yet another object of the present invention to provide a composition for reconstituted tobacco with regulated burn rate.
It is another object of the present invention to provide a composition for reconstituted tobacco with retention of tobacco characteristics.
It is a further object of the present invention to provide a smoking article, including a novel reconstituted tobacco mixed with tobacco blend.
It is yet another object of the present invention to provide a manufacturing process to provide reconstituted tobacco sheet having desired burn rate and tobacco characteristics.
It is also an object of the present invention to provide a process to make reconstituted sheets through tobacco remains or tobacco dust generated during tobacco processing, and/or tobacco leaf prime lamina strip and the like.
It is also an object of the present invention to provide a process to make reconstituted tobacco sheets, wherein said process includes casting, extrusion and the like.
It is yet another object of the present invention to reduce the tobacco dust or remains during the process of making reconstituted tobacco sheets not more than 10%
It is yet another object of the present invention is to provide a composition for reconstituted tobacco with retention of flavor compounds such as menthol.

Summary of the invention
According to one aspect of the present invention there is provided a reconstituted tobacco which can be blended with tobacco comprising 20-90%, preferably 30-80 % by weight tobacco remains, 5-70 %, preferably 8-50 % by weight HPMC, 1-30%, preferably 5-20 % by weight water soluble gum, 0.5-50 %, preferably 2-15 % by weight burn modifier, 5-50%, preferably 10-20 % by weight glycerin and 0-50 %, preferably 2-10 % by weight of filler and optionally flavoring agents.

According to another aspect of the present invention there is provided a process for reparation of reconstituted tobacco which can be blended with tobacco, comprising steps of : a) mixing 20-90% by weight tobacco remains, 5-70 % by weight HPMC, 0.5-50 % by weight burn modifier, 5-50% by weight Glycerin and 0-50 % by weight of filler, water and optionally flavoring agents to form a slurry; b) casting the slurry on a solid surface and dried and cut to the appropriate size and shape, preferably shreds of said reconstituted tobacco.

According to a further aspect of the present invention there is provided a process for preparation of reconstituted tobacco which can be blended with tobacco, comprising steps of : a) mixing 20-90% by weight tobacco remains, 5-70 % by weight HPMC, 1-30% by weight water soluble gum, 0.5-50 % by weight burn modifier, 5-50% by weight Glycerin and 0-50 % by weight of filler, water and optionally flavoring agents to form a dough, which is extruded by any means into solid forms, dried and cut to the appropriate size and shape to form said reconstituted tobacco.

Detailed Description of invention
The present invention provides novel composition for reconstituted tobacco comprising tobacco remains and film forming agents preferably hydroxypropyl methyl cellulose, humectant and burn rate modifier.
The present composition of reconstituted tobacco further comprises water soluble binding agent, preferably water soluble gum namely guar gum.
The composition for reconstituted tobacco may comprise neutral filler, preferably cellulose.
According to the present invention, the novel composition for reconstituted tobacco comprises desired flavor or any masking agent.
The present invention also provides a process for manufacturing the reconstituted tobacco wherein the said process achieves reconstituted tobacco with desired characteristics.
The composition for reconstituted tobacco is designed to manufacture a smoking article.
According to a preferred embodiment of the present invention the said novel composition of the present invention comprises tobacco and film forming agent composition comprising binding agent, burn modifiers, fillers, humectant and other additives such as desired flavor or any masking agent.
The composition of the present invention is made of any processed or raw tobacco or tobacco remains and film forming agent preferably hydroxypropyl methyl cellulose, binding agent, filler, humectant and burn modifier.
The composition is formulated into reconstituted tobacco, which may be optionally added with flavor or masking agent.
The composition preferably comprises tobacco remains or processed tobacco in amount from 20 to 90% by weight; film forming agent in amount from 5 to 70% by weight; filler in an amount from upto 40% by weight, burn modifier from 0.5-50% by weight; humectants from 5-50% by weight and flavor or masking agents as desired.
According to a most preferred embodiment of the present invention the composition comprises 20-90% by weight tobacco remains, 5-70% by weight HPMC, 0.5-50 % by weight burn modifier, 5-50% by weight Glycerin and 0-50% by weight of filler and optionally flavoring agents.
Burn modifiers according to the present invention can be selected from alkali metal salts comprised of citrate, tartrate, acetate, malate, nitrate, preferably potassium and sodium salts or a combination thereof. Further burn modifiers can be selected from hydroxides and carbonates of alkaline metal salts, preferably magnesium and calcium salts, borax or a combination thereof. Further, burn modifiers can be selected from silica and chloride of potassium and sodium.
The present invention aims to re-use / effective utilization of the tobacco dust and not to re-generate / eliminate the dust during the reconstituted sheet formation, preferably not exceeding 10%.

It is known that when burn modifiers are added along with the regular tobacco blend, the moisture content shoots up to more than 20% and hence it is highly impossible to include the modifiers into a tobacco containing article. Further it has been observed in the past that use of burn modifiers when present in tobacco containing article such as cigarettes produces, stain spots on the cigarettes, and also interferes with the sensory profile. However in the present invention it has been observed that 0.5-50% by weight of burn modifiers can be incorporated into a tobacco containing article. the present inventors have observed that, below 0.5% it does not show any positive effect. It is important to note that higher quantity of burn modifiers e.g. >15wt% can not be accommodated in a tobacco containing article using conventional routes. However, the present invention, through its composition and cast / extrusion process route, made inclusion of high amount of burn additives possible without any hurdle and without affecting the moisture content.
Burn modifiers may be classified as below -
Burn rate enhancers: Atleast one selected from the group consisting of oxides, nitrates, citrates, phosphates of alkali and/or alkaline earth metals.
Burn rate retardants: Silicates and/or hydroxides
Fillers according to the present invention can be selected from cellulose, pulp, non-tobacco plant part selected from leaf, twigs, branch, bark, bole and root.
Film forming agent includes HPMC, CMC or the like.
Water soluble gum includes guar gum, tamarind gum, acacia gum, gum ghatti, maize gum, gluten, casein.
Optionally, the formulation may contain preservatives such as sodium benzoate, calcium propionate etc.
Typically the reconstituted tobacco according to the present invention may contain the following components as mentioned in the below Table 1.

Table 1
Ingredients Quantity in range
Tobacco 20-90
Adhesive composition (HPMC) 5-70
Burn modifier 0.5-50
Binding agent 1-30
Humectants-Glycerin 5-50
Filler 0-50
Flavor (menthol) Qs
Preservative sodium benzoate (optional) 0-5

The criticality of the present invention resides in the selective choice of components and their quantity to achieve desired reconstituted sheet quality of the present invention. The sheet made out of the present invention is pliable, not brittle, importantly; the said sheet is ready to make into regular cigarettes, which is achievable only when it is able to cut in appropriate flake size. Further, yet another challenge overcome by the present invention is the considerable reduction in the dust formation during or post recon sheet formation for which the composition plays a very critical role.
When tried with tobacco content beyond the limits of the present invention, i.e. beyond 20-90% the sheet impacts the sensorial profile and also generates more dust which is highly unacceptable. When the adhesives and gum are used beyond the limits, it attributes to extreme pliability which becomes unusable and it pose challenges in sheet formation (casting process) and/or extrusion process. Hence to achieve the very purpose of the present invention to effectively utilize the tobacco remains, which is generated after the regular cigarette making process. The dust generation based on the present invention is not more than 10%.
Another advantage of the present invention is, it retains the flavor (e.g. menthol, clove etc.) in a much more simplified manner through the said process especially extrusion. Traditionally, to sustain the flavor in tobacco blend and cigarette or to add any herbal extracts (e.g. fennel), encapsulation process followed by adding into tobacco is used, which is highly complex, technically non feasible and commercially unsuccessful. This has been overcome by the present invention. The present invention is thus of economic significance and simplified the current industrial practices in making reconstituted tobacco sheets/shreds/flakes with multifaceted benefits.
Process of making reconstituted tobacco
The reconstituted tobacco sheet of the proposed invention is prepared by the process where tobacco remains is mixed with film forming agent, burn modifier, humectant, filler and water and made into slurry. Finally the slurry is cast on a solid surface, dried and cut to the appropriate size and shape, preferably shreds.
Thus in one embodiment of the invention there is provided a casting method for effective preparation of reconstituted shreds, which is mixed with tobacco blend to finally fill in cigarette tube. According to the present invention, generally, if the process (either casting / extrusion) produces less than 10% of tobacco dust is acceptable. In the said process, no tobacco dust (0%) has been generated which is highly significant. The casting method comprises the following steps:
a) heating the water content to 80°C,
b) adding the required quantity of film forming agent to the hot water with continuous stirring,
c) cooling the solution to the ambient temperature,
d) addition of the tobacco powder to the above solution with continuous stirring,
e) addition of filler content to the slurry,
f) preparation of aqueous solution of burn modifiers and addition to the slurry,
g) addition of humectants and preservatives (optional) to the slurry.
h) pouring the slurry of step (g) on to a continuous belt, made of plastic or any metal to form a thin layer of slurry,
i) drying the thin layer of slurry under mild temperature between 30-70°C to the moisture content less 20% to obtain reconstituted tobacco sheet.
In the casting process, the temperature is maintained at 30-70° C and the moisture content is maintained below 20%. When the temperature is >70° C or the moisture is more than 20% , it was observed that the sheet did not get release from the processing belt.
The reconstituted tobacco sheet thus obtained can also be used as a wrapper to wrap the tobacco blend composition to finally manufacture a smoking article.
The layer thus obtained can be cut to size with 1mm width and 15 mm long.
These shreds can be mixed with tobacco blend and used to make the cigarette. It is important to note that, there is 0% dust formed during the said process, which is one of the major objectives of the present invention.
According to a further embodiment of the present invention there is provided a extrusion method wherein the formulation is converted directly into dough, which is extruded by any means into solid forms, dried and cut to the appropriate size and shape to be used in the smoking article. This process has generated not more than 9% of dust which is still within the acceptable limits of the present invention. The extrusion process comprises the steps of:
i) mixing tobacco remains together and grinding the mixture.
ii) adding dry HPMC and binding agent to the ground tobacco of step (i) with continuous agitation in a blender,
iii) making aqueous solution of burn modifier and preservative and adding to above dry mix of tobacco mixture,
iv) adding sufficient quantity of water to the mix and making dough,
v) adding glycerin followed by mixing into the dough,
vi) extruding said dough through an orifice in such a way to obtain strips of 1mm thick and 10mm wide,
vii) drying the strips to bring down the moisture content at between 13-25%, preferably 18%,
viii) cutting the strips at 100 cuts per inch and dried to reduce the moisture content upto 14%.
It is surprising to note that the during cutting of either sheet or strips as obtained by following casting and extrusion process, to shreds of desired size generates an acceptable amount e.g. less than 10% of dust and thereby leading to higher yield of cut shreds.
It was noted that HPMC is essential in both the routes (both casting & extrusion) whereas, cellulose is essential in extrusion route.
The reconstituted tobacco sheet thus obtained can also be used as a wrapper to wrap the tobacco blend composition to finally manufacture a smoking article.
According to the present invention, the reconstituted tobacco thus obtained from the said composition is added to the tobacco blend used in smoking article manufacturing. Further the manufacturing process of the present invention achieves reconstituted tobacco, which has desired processing and tobacco characteristics.

The present invention is now disclosed by way of non-restrictive illustrative examples.

Example 1
25 gms of an adhesive composition (hydroxypropyl methyl cellulose) is dissolved in 200 ml of water at 80OC, followed by cooling to ambient temperature. To this composition 60 gms of tobacco remains, 0.5 gms of filler, 1.5 gms of burn modifier and 3 gms of humectant are added (Table 2). The mixture slurry is then casted into sheet, dried and cut to the size resembling cut tobacco blend. The tobacco blend with reconstituted shreds is then used to make the cigarettes. It is important to note that the dust generation in the formulation and process according to the present invention as described generates 0% dust (when sheet is made through casting process) and therefore offers 100% utilization of the tobacco remains.
The cigarette thus made is found to be at par with control with no unpleasant sensory experience.
Table 2: Composition for reconstituted tobacco
Ingredients Quantity (%)
Tobacco 60
Adhesive composition (HPMC) 25
Burn modifier (Potassium nitrate) 5
Humectant (Glycerin) 9.5
Filler (cellulose) 0.5
Flavor (menthol) qs
Preservative sodium benzoate (optional) 0-5
Tobacco: Any processed or raw tobacco or tobacco remains

Alternatively the tobacco is mixed with adhesive composition (HPMC and guar), followed by adding 100 ml of water solution containing 1.5 gm of burn modifier and 3 gm humectant (Table 3), kneaded in the form of dough and extrude mechanically using suitable extruder. The extruded reconstituted tobacco rods, dried followed by processing to cut to size suitable for mixing with cut tobacco blend by following the process as described above. It is observed that the dust generation in the formulation and process according to the present invention as described generates not more than 10% of dust and therefore offers significant utilization of the tobacco remains.
Table 3: Composition for reconstituted tobacco
Ingredients Quantity (%)
Tobacco 70
Adhesive composition (HPMC+Guar gum) 20 (50:50)
Burn modifier (potassium nitrate) 1.5
Humectant-Glycerin 3
Filler 0.5
Flavor Qs
Preservative sodium benzoate (optional) 0-5

The above composition has been converted into dough as per the process as described above and extruded in the form of strips. The moisture content of said strips has been reduced to 18%. The strips, thus dried were cut at 100 cuts per inches using a regular cutter. The cut particles obtained were 10 mm long, 0.22 mm thick, and 0.9 mm wide and perfectly amenable with remaining tobacco blend for cigarette making. It is important to note that during cutting there is only 8% of the dust generated, which indicates the significant utilization of the tobacco remains and thereby lends itself to cost advantages in multifaceted ways.

Example 2
Different reconstituted sheets were prepared using different compositions to show the criticality of the present invention
Sheet made out of cast route: (Positive example)
Table 4
Ingredients Wt%
Tobacco 38
HPMC 38
Glycerin 15
Borax 7
Sodium benzoate 0.38
Water qs
Sheets made out of this route with the above composition, does not create any dust (0%).

Sheet made out of Extrusion route: (Positive example)
Table 5
Ingredients Wt%
Tobacco 69
HPMC 8
Guar 8
Sodium benzoate 0.9
Potassium nitrate 0.9
Potassium citrate 1.2
Glycerin 12
Water qs
Sheets made out of this route with the said composition, does not create dust more than 8%.

Negative example- Casting route: (The table below demonstrates the importance of the amounts of the components of the present invention).
Table 6
Ingredients Wt%
Tobacco 95
HPMC 3
Glycerin 1
Sodium benzoate 0.5
Potassium nitrate 0.5

The above data demonstrates that how the ingredients and the quantity plays a vital role. For instance, when tobacco is chosen more than 90% (the present invention claims the range of 20-90%), it chokes up the system. The sheet made was not able to remove from the processing belt.
As far as process parameters are concerned for casting route, the temperature needs to be maintained at 30-70 deg C and the moisture needs to be maintained below 20%. When it is >70 deg C or the moisture is more than 20% the sheet did not get released from the processing belt.

Extrusion route (negative example): (The table below demonstrates the importance of the amounts of the components of the present invention).
Table 7
Ingredients Wt%
Tobacco 93
HPMC 2
Glycerin 2
Sodium benzoate 0.5
Potassium nitrate 0.5
Guar 2

The sheet made out of this route, generates more than 10% of dust and the moisture content was <13%, which is highly unacceptable and also defeats the purpose of the present invention.
Further it was observed that when the tobacco content is used below 20%, the major disadvantage is, it produced off-note which is also known as unacceptable sensorial profile, because there was less tobacco and the other ingredients such as HPMC, burn enhancers etc in the composition contributes for off note.
Further the objective of the present invention is to re-use the tobacco dust generated during the conventional cigarette making process; however using 20% or less amount of tobacco dust, does not serve the purpose. It also attracts major cost implications.

Example 3
Experiments had been conducted to demonstrate how the output of the present invention can be utilized to control the burn rate of a cigarette, if the reconstituted tobacco as described in present invention is used as a part of the blend.
The shreds made according to the present invention have been mixed with tobacco blend. Cigarettes have been made using 20% of reconstituted tobacco as prepared according to present invention. The said cigarettes have been smoked by following standardized protocol for burn rate.
Table 8: Comparison of burn time (control vs samples)
S. No Type of Cigarette Burn time in minutes
1 Control 8.69
2 Sample 1 (with high burn rate)* 6.06
3 Sample 2 (with low burn rate)** 9.64
*high burn rate means, within a short time, extinguishes after completely burnt.
** low burn rate means, takes longer time to extinguish.
It is clearly evident from above example that burn rate and hence total burn time can be controlled using the reconstituted as a part of tobacco blend.

Sample 1 (with high burn rate)
Table 9
Ingredients Wt%
Tobacco 37
HPMC 37
Potassium nitrate 7
Potassium citrate 2
Glycerin 15
Sodium benzoate 0.8
Water Qs

Sample 2 (with low burn rate)
Table 10
Ingredients Wt%
Tobacco 63
HPMC 9
Guar gum 8
Magnesium hydroxide 3
Borax 6.2
Glycerin 11
Sodium benzoate 0.9
Cellulose 0.6

Example 4
The present inventors had undertaken the following experiments 1) negative example 2) cast method (positive example) and 3) extrusion technique, (positive example) to show the criticality of the components of the present invention:

Negative example
Preparation of a reconstituted sheet was attempted with the composition as mentioned in Table 11
Table 11
Ingredients Quantity
Tobacco 90gm (with particle size of 0.5mm)
Guar gum 8gm
Glycerin 2gm
Water Qs
Inference: The slurry is casted on plastic belt. The sheet was formed, however could not be released form the belt collected and therefore no reconstituted tobacco was formed.
Whereas, according to present invention the following formulation was tried through cast method (positive example):

Sheet made out of cast route: (Positive example)
Table 12
Ingredients Wt%
Tobacco 38
HPMC 38
Glycerin 15
Borax 7
Sodium benzoate 0.38
Water qs
Inference: The slurry was prepared as cast as described above. The dried film is easily released from the belt and then cut to shreds before mixing with other tobacco blend to make cigarette. The sheet during cutting produced nil waste. Sheets made out of this route with the said composition, does not create any dust (0%).

Sheet made out of Extrusion route: (Positive example)
Table 13
Ingredients Wt%
Tobacco 69
HPMC 8
Guar 8
Sodium benzoate 0.9
Potassium nitrate 0.9
Potassium citrate 1.2
Glycerin 12
Water qs

The above formulation is converted into dough by following process as described above and extruded. The strips are then dried and cut at a specified moisture content before mixing with other tobacco blend. The cigarettes have been made using this reconstituted tobacco. The cigarettes thus made are at par in sensory with control. Sheets made out of this route with the said composition, does not create dust more than 8%.

Example 5
Menthol retention in the reconstituted tobacco over a period of time for atleast 3 months.
The formulation and process as per present invention further surprisingly offer the retention properties to the flavor added to the formulation.
Table 14
Ingredients Wt%
Tobacco 73%
HPMC 7%
Guar gum 7%
Glycerin 4%
Menthol 5%
Potassium citrate 3%
Cellulose 0.45%
Water Qs to make dough
Preservative sodium benzoate (optional) 0.9%

The above formulation is converted into dough by following process as described above and extruded. The strips are then dried and cut at specified moisture content and tested for retention of menthol for a period of 3 months.

Menthol retention study
Table 15
1 month 2 month 3 month
Menthol (%) 3.08 3.04 3.03
The above study shows that initially, the menthol (%) content was measured at 3.08 and after three months, the content was at 3.03 which show significant retention.
Since menthol like flavor compound is highly volatile, with known sublimation properties and hence retaining the same in the recon sheet is highly challenging. The present invention overcomes the said problem through the proposed formulation, the recon sheet shows high retention of flavor compounds such as Menthol for atleast 3 months time period, which is remarkable. ,CLAIMS:1. A reconstituted tobacco which can be blended with tobacco, said reconstituted tobacco comprising 20-90%, preferably 30-80 % by weight tobacco remains, 5-70 %, preferably 8-50 % by weight HPMC, 1-30%, preferably 5-20 % by weight water soluble gum, 0.5-50 %, preferably 2-15 % by weight burn modifier, 5-50%, preferably 10-20 % by weight glycerin and 0-50 %, preferably 2-10 % by weight of filler and optionally flavoring agents.
2. The reconstituted tobacco as claimed in claim 1, wherein said water soluble gum is guar gum.
3. The reconstituted tobacco as claimed in claim 1, wherein said filler is cellulose.
4. The reconstituted tobacco as claimed in claim 1, wherein said burn modifier is selected from alkali metal salts of citrate, tartrate, acetate, malate, nitrate; hydroxides and carbonates of alkaline metal salts; silica and chloride of potassium and sodium or combinations thereof.
5. The reconstituted tobacco as claimed in claim 1, wherein said reconstituted tobacco retains the flavor compounds for a period for atleast three months.
6. The reconstituted tobacco as claimed in claim 1, wherein said flavoring agents is selected from the group menthol, eugenol, mint, citrus, and orange flavor.
7. A process for preparation of reconstituted tobacco which can be blended with tobacco, comprising steps of:
a) mixing 20-90% by weight tobacco remains, 5-70 % by weight HPMC, 0.5-50 % by weight burn modifier, 5-50% by weight Glycerin and 0-50 % by weight of filler, 1-30% by weight of gum, water and optionally flavoring agents to form a slurry.
b) casting the slurry on a solid surface and dried and cut to the appropriate size and shape, preferably shreds of said reconstituted tobacco.
8. A process for preparation of reconstituted tobacco which can be blended with tobacco, comprising steps of : a) mixing 20-90% by weight tobacco remains, 5-70 % by weight HPMC, 0.5-50 % by weight burn modifier, 5-50% by weight Glycerin and 0-50 % by weight of filler, water, 1-30% by weight of gum, and optionally flavoring agents to form a dough, which is extruded by any means into solid forms, dried and cut to the appropriate size and shape to form said reconstituted tobacco.
9. The process as claimed in any of claims 7 and 8, wherein said process generate tobacco dust in the range between 0-10%.
10. The process as claimed in any of claims 7 and 8, wherein said flavoring agents is selected from the group menthol, eugenol, mint, citrus, and orange flavor.
11. The process as claimed in any of claims 7 and 8, wherein said water soluble gum is guar gum.
12. The process as claimed in any of claims 7 and 8, wherein said filler is cellulose.
13. The process as claimed in any of claims 7 and 8, wherein said burn modifier is selected from alkali metal salts of citrate, tartrate, acetate, malate, nitrate; hydroxides and carbonates of alkaline metal salts; silica and chloride of potassium and sodium or combinations thereof.