Method for the preparation of a cast sheet of homogenized tobacco material

1. A method for the preparation of a cast sheet of homogenized tobacco material, said method comprising:

pulping cellulose fibres with water;

grinding a blend of tobacco of one or more tobacco types to tobacco particles;

combining the pulped cellulose fibres with the tobacco particles and with a binder to form a slurry;

homogenizing the slurry;

casting the slurry to form a cast sheet of homogenized tobacco material from the slurry;

discarding undesired portions of the cast sheet; and

introducing the discarded undesired portions of the cast sheet into the slurry;

wherein the method further comprises:

selecting a total amount of tobacco to be present in the slurry in dry weight;

determining an amount of tobacco in dry weight present in the discarded undesired portions of the cast sheet introduced in the slurry; and

adding an amount of tobacco particles to the slurry in order to reach said selected total amount of tobacco in the slurry when summed to the amount of tobacco present in the discarded undesired portions of the cast sheet already introduced in the slurry.

2. A method for the preparation of a cast sheet of homogenized tobacco material, said method comprising:

forming a first batch of slurry, said first formation comprising:

pulping cellulose fibres with water;

grinding a blend of tobacco of one or more tobacco types to tobacco particles;

combining the pulped cellulose fibres with the tobacco particles and with a binder to form a slurry;

homogenizing the slurry;

casting the slurry to form a cast sheet of homogenized tobacco material from the slurry;

discarding undesired portions of the cast sheet; and

forming a second batch of slurry, said second formation comprising:

pulping cellulose fibres with water;

grinding a blend of tobacco of one or more tobacco types to tobacco particles;

combining the pulped cellulose fibres with the tobacco particles and with a binder to form a slurry;

homogenizing the slurry; and

introducing the discarded undesired portions of the cast sheet into the slurry;

wherein the method further comprises:

selecting a total amount of tobacco to be present in the slurry in dry weight;

determining an amount of tobacco in dry weight present in the discarded undesired portions of the cast sheet introduced in the slurry; and

adding an amount of tobacco particles to the slurry in order to reach said selected total amount of tobacco in the slurry when summed to the amount of tobacco present in the discarded undesired portions of the cast sheet already introduced in the slurry.

3. The method according to claim 1 , wherein the step of introducing the discarded undesired portions of the cast sheet into the slurry takes place before combining the pulped cellulose fibres with the tobacco particles.

4. The method according to claim 3 , including mixing the discarded undesired portions of cast sheet with the pulped cellulose fibres before the step of combining the tobacco particles with the pulped cellulose fibres.

5. The method according to claim 1 , including the step of:

blending one or more the following tobaccos types:

Bright tobacco;

Dark tobacco;

Aromatic tobacco;

Filler tobacco;

to obtain the blend of tobacco of one or more tobacco types.

6. The method according to claim 1 , including the steps of:

combining the binder with an aerosol-former; and

adding the combination to the slurry.

7. The method according to claim 1 , including the steps of:

pulping cellulose fibres with water and adding the pulped fibres to a tank;

adding the binder to the tank;

adding the tobacco particles to the tank; and

adding the discarded undesired portions of the cast sheet into the tank before adding the tobacco particles.

8. The method according to claim 1 , wherein the step of introducing the discarded undesired portions of the cast sheet into the slurry takes place only if the blend of tobacco present in said discarded undesired portions of the cast sheet is the same as the blend of tobacco in said tobacco particles.

9. The method according to claim 1 , including the step of:

adding the tobacco particles and the discarded undesired portions of the cast sheet into the slurry so as to obtain a total amount of tobacco comprised between about 50 percent and about 93 percent in dry weight basis of slurry.

10. The method according to claim 1 , comprising the step of:

adding in the slurry an amount of undesired portions of cast sheet comprised between about 1 percent and about 25 percent in dry weight basis of the slurry.

11. The method according to claim 1 , comprising the step of:

drying the cast sheet of homogenized tobacco material.

12. The method according to claim 1 , comprising the step of:

adding the binder to the slurry in an amount comprised between about 1 percent and about 5 percent in dry weight basis of said slurry.

13. The method according to claim 1 , comprising the step of:

adding an aerosol-former to the slurry in an amount comprised between about 5 percent and about 30 percent in dry weight basis of said homogenized tobacco material.

14. The method according to claim 1 , comprising the step of:

adding the cellulose fibres to the slurry in an amount comprised between about 1 percent and about 3 percent in dry weight basis of said slurry.

15. The method according to claim 2 , wherein the step of introducing the discarded undesired portions of the cast sheet into the slurry takes place before combining the pulped cellulose fibres with the tobacco particles.

16. The method according to claim 15 , including mixing the discarded undesired portions of cast sheet with the pulped cellulose fibres before the step of combining the tobacco particles with the pulped cellulose fibres.

17. The method according to claim 2 , including the step of:

blending one or more the following tobaccos types:

Bright tobacco;

Dark tobacco;

Aromatic tobacco;

Filler tobacco;

to obtain the blend of tobacco of one or more tobacco types.

18. The method according to claim 2 , including the steps of:

combining the binder with an aerosol-former; and

adding the combination to the slurry.

19. The method according to claim 2 , including the steps of:

pulping cellulose fibres with water and adding the pulped fibres to a tank;

adding the binder to the tank;

adding the tobacco particles to the tank; and

adding the discarded undesired portions of the cast sheet into the tank before adding the tobacco particles.

20. The method according to claim 2 , wherein the step of introducing the discarded undesired portions of the cast sheet into the slurry takes place only if the blend of tobacco present in said discarded undesired portions of the cast sheet is the same as the blend of tobacco in said tobacco particles.

21. The method according to claim 2 , including the step of:

adding the tobacco particles and the discarded undesired portions of the cast sheet into the slurry so as to obtain a total amount of tobacco comprised between about 50 percent and about 93 percent in dry weight basis of slurry.

22. The method according to claim 2 , comprising the step of:

adding in the slurry an amount of undesired portions of cast sheet comprised between about 1 percent and about 25 percent in dry weight basis of the slurry.

23. The method according to claim 2 , comprising the step of:

drying the cast sheet of homogenized tobacco material.

24. The method according to claim 2 , comprising the step of:

adding the binder to the slurry in an amount comprised between about 1 percent and about 5 percent in dry weight basis of said slurry.

25. The method according to claim 2 , comprising the step of:

adding an aerosol-former to the slurry in an amount comprised between about 5 percent and about 30 percent in dry weight basis of said homogenized tobacco material.

26. The method according to claim 2 , comprising the step of:

adding the cellulose fibres to the slurry in an amount comprised between about 1 percent and about 3 percent in dry weight basis of said slurry.