United States Patent [19J
`Sensabaugh et al.
`
`[I I] Patent Number:
`[45] Date of Patent:
`
`4,660,577
`Apr. 28, 1987
`
`[75]
`
`[54] DRY PRE-MIX FOR MOIST SNUFF
`Inventors: Andrew J. Sensabaugh; Ronald L.
`Parks, William P. Mangan, all of
`Winston-Salem; Arvol C.
`Marsh, Rural Hall, all of N.C.
`
`[73] Assignee: R.J. Reynolds Tobacco Company,
`Forsyth, N.C.
`[21] Appl. No.: 741,028
`Jun.3, 1985
`[22] Filed:
`
`[51]
`
`Related U.S. Application Data
`[63] Continuation of Ser. No. 410,091, Aug. 20, 1982, aban(cid:173)
`doned.
`Int. CI.4 .......................... A24B 3/12; A24B 3/18;
`A24B 15/20
`[52] U.S. CI . .................................... 131/352; 131/290;
`131/300; 131/303; 131/308; 131/310
`[58] Field of Search ............... 131/742, 290, 324, 300,
`131/302, 303, 308, 309, 3 IO, 352
`
`[56]
`
`References Cited
`U.S. PATENT DOCUMENTS
`4,392,501 7/1983 Nealton et al. ..................... 131/290
`
`OTHER PUBLICATIONS
`Tobacco Dictionary edited by R. Jahn, Philosophical
`Library, N.Y., U.S.A., date 3/11/1955.
`
`Primary Examiner-V. Millin
`Attorney, Agent, or Firm-Kenyon & Kenyon
`
`ABSTRACT
`[57]
`A dry pre-mix is provided whereby a moist snuff can be
`prepared by addition of water. The pre-mix consists of
`a mixture of snuff-type tobaccos, cut to a predetermined
`size and having a moisture level between 6% and 16%.
`
`10 Claims, No Drawings
`
`RJRV EX 1017
`Page 1
`
`

`

`1
`
`DRY PRE-MIX FOR MOIST SNUFF
`
`4,660,577
`
`This is a continuation of co-pending application Ser.
`No. 06/410,091 filed on Aug. 20, 1982, now abandoned. 5
`
`BACKGROUND OF THE INVENTION
`This invention relates to a novel tobacco product.
`More particularly, the invention relates to a dry, finely(cid:173)
`cut tobacco mixture, to which a consumer may add IO
`water to produce moist snuff.
`Snuff is one of the oldest tobacco products known.
`Two types exist, dry snuff and moist (or wet) snuff. The
`former is produced as a dry powder. The latter product
`is produced from similar tobacco blends but is finely cut 15
`rather than ground, and it has a high moisture level. The
`present invention concerns moist snuff, and further
`discussion will be limited to that product.
`The properties of snuff, as with any tobacco product,
`are determined primarily by the tobacco blend and 20
`processing variables. Important variables include the
`temperature/time relationship during processing, the
`cut, casing, top dressing, and final moisture content.
`The tobacco blend is crucial to achieving proper
`snuff flavor and color characteristics. For example, 25
`cigarette
`tobacco blends normally
`include
`large
`amounts of Burley, Flue-cured, and Turkish tobaccos.
`Snuff derives many of its characteristics from the use of
`"snuff-type" tobaccos, such as Dark Fired, Green
`River, and One-Sucker tobaccos, primarily from Ten- 30
`nessee and Kentucky. Snuff-type tobaccos can be char(cid:173)
`acterized chemically by a high level of nitrogenous
`constituents, particularly nicotine. Physically, these
`tobaccos are heavy-bodied, having long wide leaves.
`Use of these types of tobacco is dictated by consider- 35
`ations of flavor and the ability to withstand processing;
`other type tobaccos tend to degrade physically when
`subjected to snuff processing. A modern snuff mixture
`might also contain a significant percentage of other
`tobacco materials, such as rolled stems. A traditional 40
`snuff blend, for example, could contain 70% Dark Fired
`tobacco, 10% each of One-Sucker and Green River,
`with 10% of a more common tobacco variety, such as
`Burley. To provide the taste and color characteristics
`the consumer has come to expect from snuff, however, 45
`the blend's major constituents must be snuff-type tobac-
`cos.
`Casing and top dressing (flavoring) is extensively
`used in snuff production. The distinction between these
`two operations is that casing materials normally are
`applied during processing operations, while top dress(cid:173)
`ing, or final flavoring, usually is applied as a final, or
`near-final step. A wide variety of flavorants has found
`acceptance among snuff consumers. Mint, attar of rose,
`fruit, and wintergreen flavors enjoy considerable mar(cid:173)
`ket acceptance.
`The time-temperature relationship in snuff manufac(cid:173)
`turing differs considerably from other tobacco pro(cid:173)
`cesses. Traditionally, the snuff manufacturing process
`requires up to 18 months, in addition to the two-four
`years' storage in hogsheads. Even though modern tech(cid:173)
`niques have reduced processing time to the three to four
`month range, the processing scheme closely follows
`traditional methods. Tobacco is removed from the
`hogsheads, at which time it has a moisture content be(cid:173)
`tween 20 and 22%. Casing material is added, raising the
`moisture level above about 40%. The wet tobacco is
`then stored at room temperature, producing an environ-
`
`2
`ment highly conducive to bacterial growth. The result(cid:173)
`ing fermentation releases heat, raising the temperature
`of the mixture and promoting further bacterial growth
`and fermentation. This process is allowed to continue 60
`to 90 days, until the manufacturer is _satisfied that a
`proper flavor level has been achieved. The decision to
`proceed with processing relies upon art rather than pure
`science. The primary differences between traditional
`and modern processing methods are the realization that
`acceptable flavoring can be produced in reduced time,
`and the use of cold storage to abort the fermentation
`when desired flavor levels are achieved.
`Different tobacco products are also characterized by
`different techniques used in cutting the tobacco. In all
`snuff manufacturing, however, tobacco strips (the por(cid:173)
`tions of the tobacco leaf remaining after removal of the
`stems) are subjected to a double cutting process. The
`standard measure of tobacco cutting processes is the
`number of cuts made per inch of tobacco strip. For
`example, cigarette tobacco filler undergoes about
`thirty-two cuts per inch. Here, the moist snuff tobacco
`initially is coarsely shredded at about twenty cuts per
`inch, and after fermentation, it is subjected to a second
`cutting process. Rather than shredding, here the to(cid:173)
`bacco is run through a hammer mill, where the tobacco
`is comminuted into small particles. This second cutting
`process is roughly equivalent to a single cut at about
`ninety cuts per inch.
`Moisture content has proven crucial to consumer
`perception of snuff quality. Unlike other tobacco pro(cid:173)
`cesses, the moisture content is not carefully controlled
`and varied during processing; rather, final moisture
`content adjusted to a desired level immediately prior to
`packing. Moist snuff processing further is unique in that
`the entire process is conducted at elevated moisture
`levels. After the initial addition of casing material, the
`tobacco remains above the 40% moisture level, and it
`must be packed at a moisture level between 48 and 55%.
`This level has proved a crucial variable, because cus(cid:173)
`tomers can perceive moisture differences of as little as
`3% and will reject such a product as being too dry and
`too light in color.
`Maintaining an acceptable moisture level between
`production and consumption is the major problem fac(cid:173)
`ing moist snuff producers. The product tends to lose
`moisture in the packing process, and it experiences addi-
`tional moisture losses after packaging. Moist snuff nor(cid:173)
`mally is marketed in a cardboard, wax-coated container
`which is highly permeable to moisture. Tests reveal that
`50 if such a container is allowed to remain unopened at
`room temperature for sixty days, moisture content of
`the product will drop from 55% to 32%. Long before
`that point, of course, the product would have become
`unacceptable to consumers. Replacement of the normal
`55 packaging material with an hermetically sealed con(cid:173)
`tainer would not solve this problem, because the fer(cid:173)
`mentation process is continuing, albeit at a low level.
`Even at a low level, however, some gas is evolved.
`Thus, an hermetically sealed container would result in
`60 unacceptable pressure buildup inside, leading to bulg(cid:173)
`ing, buckling, and ultimate failure of the container.
`Plastic containers, recently tested as replacements for
`the traditional cardboard, have featured vent holes to
`allow gas to escape. Because moisture will also escape
`65 through such holes, changing the packaging material
`will not eliminate this seemingly inherent problem of
`moist snuff. Of course, moisture loss accelerates after
`the can has been opened.
`
`RJRV EX 1017
`Page 2
`
`

`

`4,660,577
`
`3
`This problem has led to moist snuff being marketed as
`a highly perishable product. The combination of mois(cid:173)
`ture loss and the small amount of product consumed at
`one time has dictated a small package; the container
`normally used in the art contains only 1.2 ounces. Fur- 5
`ther, a leading producer of moist snuff date stamps each
`can and has established a distribution system that rap(cid:173)
`idly moves the product from the factory to the shelf,
`apparently the only possible response to consumer de(cid:173)
`mand for fresh product. Consumer surveys demonstrate IO
`that snuff users look for fresh product and are willing to
`go out of their way to find it.
`Given the limitations inherent in the product, the
`prior art has found no solution to the problem of obtain(cid:173)
`ing a moist snuff having a stable shelf life. Rather, the 15
`industry seems content to maintain the existing cumber(cid:173)
`some and expensive distribution system and to endure
`spoilage and consumer dissatisfaction.
`
`30
`
`4
`produce browning reactions in
`the sugars present
`therein. These reactions result in darkening the tobacco
`and producing snuff flavor precursors. The tobacco
`mixture emerges from the previous casing step at a
`temperature between about I 60° and 190° F. (7 I 0 -88°),
`preferably I 90° F. (88° C.), whereupon it is placed into
`containers. The mixture remains within these containers
`between about 24 and 48 hours. The Maillard reactions
`are.induced by maintaining the tobacco at this elevated
`temperature during the holding period. This tempera(cid:173)
`ture can be maintained by applying external heat to the
`container holding area, as with steam, or simply by
`maintaining the containers within an insulated area and
`allowing the heat liberated by the Maillard reactions to
`maintain the proper temperature. With either method,
`the tobacco temperature rises to about 200° F. (93° C.).
`The resulting product closely simulates that produced
`through traditional fermentation, but it does so in one to
`two days rather than two to three months. The product
`20 emerges from the forced aging step having a moisture
`content between JO and 14%, rather than the elevated
`moisture level of over 40% found in the prior art.
`The mixture is then fed into a cutter, of which many
`types are well-known in the art. Cutting parameters can
`be varied depending upon the desired degree of fineness
`in the finished product, within a normal range of 40-120
`cuts per inch. Applicant prefers a double cut, using two
`cutters rather than the cutter/hammer mill combination
`used in the prior art. The first cutter is set at about 32
`cuts per inch, and the second at about 90 cuts per inch.
`Here, those skilled in the art would adjust the mois(cid:173)
`ture level to 55% preparatory to packing. Applicant,
`however, proceeds directly to addition of top dressing
`to the dry tobacco. In this final step, pH may be ad(cid:173)
`justed by addition of ammonium carbonate, sodium
`bicarbonate, or other additives; salt and flavorants such
`as wintergreen or mint are added to produce the desired
`flavor, both steps being known to the art.
`The product, still having a moisture content between
`about 6 and 16%, preferably 10-14%, is then packed
`and shipped to consumers.
`Conversion of the product from a dry pre-mix to
`moist snuff occurs in the hands of the consumer. The
`exact method of conversion depends primarily upon the
`packaging means selected. One method would be to
`market the pre-mix in bulk, providing a small container
`in which the consumer could prepare moist snuff as
`needed. Another method might be to market relatively
`small containers, with instructions to prepare moist
`snuff within that container. Still another method would
`be to market the product in multi-cell flexible packag-
`ing, with one cell containing pre-mix and another con(cid:173)
`taining water. By applying pressure, the customer could
`rupture the seal between the pre-mix and the water, and
`simply by kneading the resulting mixture, produce
`moist snuff.
`It should be understood that variations in the method
`of production and in the product itself will be obvious
`to those having skill in the art. For example, the propor(cid:173)
`tions or types of snuff-type tobaccos may be altered, or
`the time/temperature relationships could be varied to
`produce desired flavors. Such variations are included
`within the scope of the present invention.
`I claim:
`1. A dry pre;mix for making moist snuff by later
`addition of water, comprising an aged tobacco blend
`containing at least 50% snuff-type tobaccos and snuff
`flavor precursors, having a moisture content between
`
`SUMMARY OF THE INVENTION
`Applicant has discovered that it is possible to provide
`a tobacco product at a low moisture level, to which the
`consumer can add a measured quantity of water to
`produce moist snuff. Elimination of the moisture level
`problem will free the industry from the burdens of small 25
`containers, cumbersome distribution, and extensive con(cid:173)
`sumer dissatisfaction. The product can be provided to
`customers either in bulk or in suitable containers which
`permit easy and accurate measurement for addition of
`the correct amount of water.
`An object of this invention is to provide a dry to(cid:173)
`bacco product which, when mixed with the correct
`amount of water, will produce a moist snuff.
`A further object of this invention is to produce a
`tobacco product, to be consumed as a moist snuff, hav- 35
`ing a substantially longer shelf life than presently
`known moist snuff products.
`Another object of this invention is to provide a moist
`snuff product which will allow consumers to obtain
`product in reasonable quantities, without sacrificing 40
`freshness.
`
`DETAILED DESCRIPTION OF THE
`INVENTION
`Dry pre-mix for moist snuff is produced in a manner 45
`radically different from the traditional moist snuff pro(cid:173)
`cess. Initially the aging process is reduced to a maxi(cid:173)
`mum of two to three years in hogsheads, and the mois(cid:173)
`ture content upon removal from the hogsheads is in the
`range 12-14%. The tobacco is then blended, using tech- 50
`niques and apparatus known in the art. Either before or
`after blending, the moisture level is adjusted to about
`12-18% in apparatus such as reordering drums, nor(cid:173)
`mally employing steam conditioning. The exact blend
`may vary according to the taste characteristics desired, 55
`but snuff-type tobaccos should constitute the major
`portion of the mixture. Applicant's preferred embodi(cid:173)
`ment consists of 5-25% Dark Fired tobacco, 10-30%
`Green River, 30-50% One-Sucker and up to 40% other
`tobacco materials. At this stage, casing materials such as 60
`water, licorice, flavorants, and sugars may be added to
`the tobacco. This step normally is carried out at an
`elevated temperature, preferably 140°-180° F. (60°-82°
`C.)
`At this point, the tobacco enters a forced aging stage. 65
`Forced aging simulates the result of the traditional fer(cid:173)
`mentation step by inducing natural chemical reactions,
`known as Maillard reactions, in the tobacco, which
`
`RJRV EX 1017
`Page 3
`
`

`

`4,660,577
`
`5
`about 6 and 16%, and comminuted into particles, sub(cid:173)
`stantially all of said particles having a width between
`about 1/40 and 1/120 inch (0.6 and 0.2 mm) wide.
`2. The dry pre-mix of claim 1, wherein said moisture
`content is between about 10 and 14%.
`3. The dry pre-mix of claims 1 or 2, wherein said
`comminuted particles have a width of about 1/90 inch
`(0.28 mm).
`4. A process for producing a dry pre-mix for making 10
`moist snuff by later addition of water comprising the
`steps of
`providing select tobaccos including snuff-type tobac(cid:173)
`cos for blending;
`blending said tobaccos to produce a blended tobacco 15
`containing at least 50% snuff-type tobaccos;
`cutting the blended tobacco into comminuted parti(cid:173)
`cles having a width between about 1/40 and 1/120
`inch;
`casing the cut blend with flavorants and water;
`thereafter elevating the temperature of the cut blend
`to about 200° F. (93° C.) and maintaining said ele(cid:173)
`vated temperature for a time sufficient to force age
`the blend while producing snuff flavor precursors 25
`and imparting a final moisture content between
`about 6 and 16%;
`
`6
`adjusting the pH of the force-aged blend and adding
`flavorant to form a pre-mix; and
`packing the pre-mix.
`5. The process of claims 4, wherein said forced-aging
`5 step results in said final moisture content of said blend
`being between 10-14%.
`6. The process of claim 5, wherein said sufficient time
`for said forced-aging step is about 24 to 48 hours.
`7. The process of claims 4, 5, or 6, wherein said cut(cid:173)
`ting step cuts said blend into comminuted particles hav(cid:173)
`ing a width of about 1/90 inch (0.28mm).
`8. A dry pre-mix for making moist snuff, said pre-mix
`comprising
`a comminuted tobacco blend of aged tobacco cut to a
`degree of fineness within a range of from 40 to 120
`cuts per inch and containing casing material and
`snuff flavor precursors, a major portion of said
`blend including snuff-type tobacco characterized
`chemically by a high level of nitrogenous constitu(cid:173)
`ents; and
`moisture in an amount of between 6% to 16%.
`9. A dry pre-mix as set forth in claim 8 wherein said
`moisture is in an amount between 10% and 14%.
`10. A dry pre-mix as set forth in claim 8 characterized
`in being able to absorb moisture up to an amount of
`from 48% to 55% to form a moist snuff.
`* * * * *
`
`20
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`RJRV EX 1017
`Page 4
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`

`

`:
`
`UNITED STATES PATENT AND TRADEMARK OFFICE
`CERTIFICATE OF CORRECTION
`4,660,577
`April 28, 1987
`Andrew J. Sensabaugh, et al
`It is certified that error appears in the above-identified patent and that said Letters Patent is hereby
`corrected as shown below:
`
`PATENT NO.
`DATED
`INVENTOR(S) :
`
`Face page, under Assignee, change "R.J. Reynolds Tobacco Company,
`Forsyth N.C." to -Alfred & Christian Peterson, Ltd.,
`Owensboro, Kentucky-
`
`Signed and Sealed this
`
`Twenty-seventh Day of October, 1987
`
`Attest:
`
`Attesting Officer
`
`Commissioner of Patents and Trademarks
`
`DONALD J. QUIGG
`
`RJRV EX 1017
`Page 5
`
`

`

`UNITED ST ATES PA TENT AND TRADEMARK OFFICE
`CERTIFICATE OF CORRECTION
`
`:
`
`PATENT NO.
`DATED
`INVENTOR(S) :
`
`4,660,577
`April 28, 1987
`Andrew J. Sensabaugh, et al
`It is certified that error appears in the above-identified patent and that said Letters Patent is hereby
`corrected as shown below:
`
`Column 1, line 13 "exist." should be "exist,-
`
`Column 1, line 16 "ground." should be -ground,-
`
`Signed and Sealed this
`
`Nineteenth Day of July, 1988
`
`Attest:
`
`Attesting Officer
`
`Commissioner of Patents and Trademarks
`
`DONALD J. QUIGG
`
`RJRV EX 1017
`Page 6
`
`