Application research of powder forming technology in the preparation of heated tobacco core materials

Heated tobacco core material, a key component of heated tobacco products (HTPs), functions as the primary carrier for aerosol, nicotine, and flavor compounds. However, conventional papermaking methods impose inherent limitations that compromise the overall quality of these core materials. This study proposes a novel method for producing reconstituted tobacco (RT) using ultrafine powder (UFP) derived from tobacco raw materials. Comparative analysis revealed distinct physical and chemical properties of UFP-based RT compared to traditional paper-based RT. Specifically, the UFP-based material exhibited reduced thickness (from 0.144 mm to 0.113 mm) and lower air permeability (from 84 CU to 15 CU), while showing significant improvements in tensile strength (from 726 N/m to 965 N/m), elongation (from 2.331% to 2.732%), density (from 0.659 g/cm³ to 0.779 g/cm³), thermal conductivity (from 0.0525 W/(m·K) to 0.0739 W/(m·K)), and smoothness (from 3 S to 13 S). The UFP-based substrate also demonstrated enhanced wettability, which improved coating performance during RT manufacturing. Although conventional chemical indicators were similar between the two materials, the UFP-based core contained 21.2% more volatile flavor compounds. Thermal analysis indicated a higher total weight loss (37.89% for UFP-based vs. 30.40% for conventional material) within the temperature range of 224-378 °C, along with a shift in the maximum weight loss rate from 296 °C to 287 °C for the UFP-based material. These findings highlight the superior functionality and aerosol generation potential of the UFP-processed heated tobacco core material.