WO2013030286A1

WO2013030286A1 - Tobacco reclaim from waste cigarettes

Info

Publication number: WO2013030286A1
Application number: PCT/EP2012/066873
Authority: WO
Inventors: Mansueto Favaro
Original assignee: Garbuio SpA
Current assignee: Garbuio SpA
Priority date: 2011-09-01
Filing date: 2012-08-30
Publication date: 2013-03-07
Anticipated expiration: 2014-03-01
Also published as: EP2750525B1; PL2750525T3; EP2750525A1

Abstract

An apparatus is provided for breaking down cigarettes to separate the filter portion from the tobacco portion. The apparatus includes a conveying duct (2) that conveys cigarettes in an orientation such that the longitudinal axes of the cigarettes and the conveying duct are substantially in alignment; cigarette - accommodating means (11) comprising at least one channel, the channel being configured to accommodate a cigarette, such that the longitudinal axes of the cigarette and the channel are substantially in alignment; and means for lining up the channel with the conveying duct, to allow a cigarette to be delivered from the conveying duct to the channel. The apparatus further includes a stopping surface (14) adjacent to the cigarette - accommodating means, the stopping surface being arranged to support a cigarette such that the cigarette remains partly accommodated within the channel. The stopping surface (14) is positioned such that when the cigarette is partly accommodated within the channel and supported against the stopping surface, the filter portion of the cigarette protrudes from the cigarette - accommodating means. The apparatus further includes separation means (21) for separating the protruding filter portion from the tobacco portion.

Description

Tobacco Reclaim from Waste Cigarettes

In the cigarette manufacturing process, defective cigarettes are detected and rejected automatically, and then processed to recover and re-use their tobacco content. The process of reclaiming the tobacco depends on achieving an efficient separation of tobacco from the paper and filters, whilst minimising degradation or reduction of tobacco particle size.

Existing processes for achieving this separation variously depend on sieving, mechanical deformation and shock, combined with air separation. For example, the waste cigarettes can be conveyed by airflow through a specially constructed centrifugal fan, in which impacts between the impellor blades and the cigarettes burst the cigarette paper and /or loosen the tobacco. The tobacco is then separated from the paper and filters by sieving. The

disadvantage of this method is that particles of the filter material can become dislodged and subsequently contaminate the separated tobacco. A further disadvantage is the degradation or breakage of the tobacco which may occur due to the pneumatic transport. Other methods of separation of filters from the tobacco involve slitting the cigarette paper generally along the cigarettes' longitudinal axis, thus releasing the tobacco. This also carries a risk of contaminating the reclaimed tobacco with pieces of filter material, as it is difficult to ensure that the filter is not also cut together with the cigarette paper. These existing processes can be applied to achieve relatively good separation of paper and filters from tobacco. However the introduction of more

sophisticated filters containing encapsulated or granular flavour or filtration materials requires even higher levels of separation efficiency than can be achieved by these existing means. This is because the contamination of waste tobacco with highly concentrated flavours or other materials present in these types of filters would affect the taste or aroma of the reclaimed tobacco to an unacceptable extent.

The purpose of the present invention is to separate tobacco from filters with very high efficiency so as to help to ensure that the reclaimed tobacco is free from any of the constituents of the filter. Furthermore, the tobacco is to be separated from the tobacco rod portion of the cigarette in such a way as to reduce breakage and degradation of the tobacco particle size. Detailed Description

The invention will now be described by way of example only, with reference to specific embodiments thereof.

Waste cigarettes from the manufacturing process are fed into an initial screening vibratory conveyor to remove large over-size objects, followed by an optical sorter (figure 1 ) to separate loose tobacco, loose filters and over- length cigarettes from the single cigarettes. The screening system is not the subject of the present invention, nor is the principle of optical sorting.

The optical sorter preferably but not exclusively consists of a number of approximately parallel channels (1 ) typically formed of strips of metal or plastic material and located on top of a belt conveyor (2) such that cigarettes or cigarette components can pass along the channels, driven by the belt conveyor. Sensors typically consisting of pairs of light emitting diodes and phototransistors (3) are arranged to view transversely across each channel. As a cigarette or cigarette component passes along a channel past a sensor, the output of the sensor produces a characteristic waveform depending on the nature of the cigarette or component. High speed electronic logic decodes these waveforms and generates output signals depending on the required sorting. These output signals are used to energise groups of compressed air jets (6) to divert the cigarette or cigarette component into an appropriate channel. Using this method, the cigarettes can be separated from loose components such as filters, and tobacco rods, and the cigarettes can be sorted into separate channels for those travelling with the filter first (7), and those with the filter rear-most (8).

The throughput of such an optical sorting system is limited by the maximum speed at which the cigarettes and their components can be reliably conveyed along the channels. Typically the maximum speed is estimated to be in the region of 2 m/second, which places a relatively low limit on the throughput of such a device, which is estimated to be of the order of 5 cigarettes per second per channel. Therefore to achieve higher throughputs it is necessary to arrange several parallel sorting channels.

Whilst the majority of the sorting required can be performed by monitoring the general waveform produced by the variation in the output of the sensors according to the presence of tobacco rod or filter, sorting due to length is inaccurate due to possible slippage between the cigarette components and the belt, and this effect becomes more significant at higher speeds. Therefore it is desirable to introduce one or more driving wheels or rollers (4) at positions prior to the optical sorting sensors (3), to ensure that the velocity of the components past the sensors is accurately determined. Alternatively a plurality of rollers may be similarly positioned and connected together by a band so as to form an inverted band conveyor. These driving wheels are positioned so that the vertical gap between the wheel and the conveying belt is slightly less than the diameter of the cigarettes being processed, and the circumferential speed of the wheel is equal to the linear speed of the belt. In the present embodiment, the band conveyor is divided longitudinally into narrow conveyors (2) each with two sorting channels (1 ) (see figs 1 and 2). Several identical conveyors can be located beside one another, with a small gap between each. This gap allows cigarette components such as filters and tobacco rods (ie tobacco wrapped in paper but without a filter attached) to be diverted from the sides of the conveyor, and to fall into bins or other conveying means underneath the optical sorting conveyors. (9)

In the first embodiment of the present invention, sorted cigarettes are discharged from the end of the optical sorting channels. One set of channels is dedicated to cigarettes with the filters leading (7), and the other is dedicated to filters rear-most (8).

The cigarettes travel along a tubular guide and change direction from a generally horizontal orientation on the optical sorter to a vertical orientation, moving vertically downwards under the influence of gravity or assisted by a conveying air flow.

In the case of filter-first oriented cigarettes, the cigarettes enter a cylindrical holder (1 1 ) preferably provided with four flutes, equi-spaced around its circumference (see Fig. 3). As an alternative to flutes, the cylindrical holder may be instead provided with holes located close to the circumference of the cylinder, and parallel to its axis. The diameter of the flutes or holes is chosen to be greater than the diameter of the cigarettes being processed to allow them to fall freely through the holes or flutes. The cylindrical holder is oriented with its axis vertical, and is supported on bearings so that it can rotate on this axis. It is preferably driven and positioned by a stepper motor (12).

Alternatively a servo motor may be used, or a mechanical device such as a Geneva mechanism may be used to position and rotate the cylinder from one index position to another.

The cylinder is surrounded by circumferential guides (13) which retain the cigarettes within the flutes and stops them from falling out radially. The guides may be adjustable in a direction radial to the cylinder to allow the system to be optimised for different cigarette diameters.

At the instant that a cigarette enters a cylinder flute, the cylinder is stationary. The cigarette falls vertically down the flute until the filter portion extends below the bottom face of the cylinder. The fall of the cigarette is stopped by the end of the filter resting against a static surface (14). This surface is preferably adjustable vertically, so that the protrusion of the filter portion of the cigarette below the cylinder can be precisely determined. At any time, another cigarette may approach the cylinder, but will stop and rest on a stationary cigarette that is already in position.

An optical sensor (24) is arranged to detect whether the filter end of the cigarette is in contact with the static surface (14), and thereupon provides an output signal which enables the cylinder to be rotated rapidly through an angle of 90 degrees, when it stops again. During its rotation, the filter is arrested by a static anvil (15) located approximately mid-way between the starting and stopping positions. The filter is therefore removed and physically separated from the tobacco rod portion of the cigarette due to the breakage of the cigarette wrapping paper close to the junction between the filter and the tobacco rod. Whilst the cylinder is rotating, the next cigarette to arrive may rest with its filter end rubbing on the top of the cylinder (16), until the cylinder rotation stops with an empty flute positioned underneath the cigarette. A tobacco rod is now at the second index position (17) of the cylinder, and the filter is retained at the anvil position (15). Both elements are then allowed to fall vertically from these positions, down tubular or other guide chutes (18, 19), either under the influence of gravity or assisted by air flow or other mechanical means. In an alternative embodiment, the tobacco rods are ejected from the fluted drum in a radial direction, either by means of an air jet or by mechanical means.

In the case of filter-rearmost oriented cigarettes, the cigarettes enter a cylindrical holder similar to that already described but with detail differences which is shown in fig 4. The cylinder is surrounded by circumferential guides (13) which retain the cigarette within the flutes and stops them from falling out radially. The guides may be adjustable in a direction radial to the cylinder to allow the system to be optimised for different cigarette diameters.

At the instant that a cigarette enters a cylinder flute, the cylinder is stationary. The cigarette falls vertically down the flute until the non-filter portion extends below the bottom face of the cylinder. The fall of the cigarette is stopped by the non-filter end of the cigarette resting against a static surface (14). This surface is preferably adjustable vertically, so that the protrusion of the filter portion of the cigarette above the cylinder can be precisely determined and optimised to suit the characteristics of the cigarettes being processed. An optical sensor (24) is arranged to detect whether the non-filter end of the cigarette is in contact with the static surface(14), and thereupon provides an output signal which enables the cylinder to be rotated rapidly through an angle of 90 degrees, when it stops again. During its rotation, the filter is retained by a static anvil above the cylinder (21 ), located approximately mid-way between the starting (22) and stopping positions (23). The filter is therefore removed and physically separated from the tobacco rod portion of the cigarette due to the breakage of the cigarette wrapping paper close to the junction between the filter and the tobacco rod. The loose filter can be ejected radially from the anvil position by air jet or other mechanical means. The tobacco rod is now at the second index position of the cylinder (23) and is then allowed to fall vertically from this position, down a tubular or other guide chute (18), either under the influence of gravity or assisted by air flow or other mechanical means. The filter is retained at the anvil position (21 ) and is ejected by air jet or other means in a radial direction into a chute, along which it falls or is conveyed by air flow or other means. In an alternative embodiment, the tobacco rods are ejected from the fluted drum in a radial direction, either by means of an air jet or by mechanical means.

In the embodiments illustrated in the diagrams, the fluted drum is provided with four flutes, and two cigarettes are processed in opposing flutes simultaneously. However the fluted drum could be made with a larger diameter and a greater number of flutes to enable greater numbers of cigarettes to be processed simultaneously if required.

In a further alternative embodiment, the tobacco rods are ejected

mechanically or by air jet radially from the fluted drum and conveyed with random orientation to a conventional waste tobacco reclaim system in which the tobacco is loosened from the wrapping paper by passing the rods through a radial bladed centrifugal fan. The paper and tobacco are then passed over a vibratory sieving conveyor whose mesh aperture size is between 2 and 6mm but not confined to this range. The reclaimed tobacco falls through the mesh with virtually zero contamination by paper, and is collected in convenient receptacles from the lower deck of the sieving conveyor. The paper remains on the upper sieve deck and can be similarly collected or conveyed for example pneumatically to a waste compactor.

In the embodiments so far described, (in figures 1 -4) the cigarettes are retained and processed such that they are oriented parallel to the axis of a rotating drum. In a further second embodiment described in figures 5 to 7, the cigarettes are processed whilst oriented radially to the axis of a rotating device.

Referring to Figure 5 the cigarettes discharged from the optical sorter (2) are fed through channels (7 &8) as described previously, in this case with one channel dedicated to cigarettes with the filters travelling first, and the next channel dedicated to filters travelling rear-most.

The cigarettes are directed to drums which rotate concentrically about a stationary shaft. The drums are of two types, each with identical external appearance but internal arrangements which are determined by whether the drum is intended to process cigarettes with filter first (31 ) or filter

rearmost.(32) The drums are driven by a servo or stepper motor or other mechanical means to provide rapid rotation and precise stopping at each index position.

The drum arrangement for filter-first cigarettes is shown in figure 6. At the instant that a cigarette enters a radial channel, the drum is stationary as shown in 7A. The cigarette falls through the channel as shown in fig 6B, through the drum (31 ) and the shaft (33), and is stopped when the filter rests on the circumferential guide (34). An electro-optical sensor (38) detects that the cigarette is in position, and control logic allows the drum to then be indexed to the next position. Midway between the two positions the filter is arrested as shown in fig 6B and removed by a fixed anvil (35), and the filter is allowed to fall into a collection chute for disposal. The tobacco rod portion (39) is retained within the drum as it passes over the anvil (35) and is then ejected from the drum either by gravity assisted by centrifugal force, or by

compressed air introduced via a port in the static shaft as shown in Fig 6C (37). Meanwhile the next cigarette is released from a solenoid or

pneumatically actuated holding pin (38) so that it can be fed to the drum. The filter end of that cigarette can rest on the circumference of the drum until the drum stops with the next channel correctly positioned for the cigarette to fall down it.

The filter rear-most arrangement is shown in Figure 7. In this arrangement the centre shaft (40) has no channel through it, so the cigarette (41 ) is stopped when its non-filter end rests on the surface of the static shaft (40) as shown in Fig 7B. An electro optical sensor (42) detects that the cigarette is sufficiently inserted into the drum channel and control logic allows the drum to then be indexed to the next position. The drum (32) then makes a series of rotational index movements, with each index repeating the actions already described. As the cigarettes reach the lowermost index positions, they fall out radially due to gravity assisted by centrifugal force, and are arrested by their filter ends contacting the circumferential guide (34). The filters are removed by impact with a fixed anvil (35) as described previously, and the tobacco rods are also ejected as described previously for the filter first drum arrangement, as shown in fig 7C.

Referring to Fig 9, In the case of the third embodiment filter removal device, it is preferable for the device is to be fed with cigarettes filter first, so that their axial positions within it are determined with reference to the filter end of the cigarettes since this part of the cigarette is the firmest and least likely to be damaged.

The third embodiment filter removing device consists of two endless bands (60) each passing around a drive roller (61 ) at one end and a free running tail roller (62) at the other. The drive rollers (61 ) are driven by stepper motors or servo motors such that they can be stopped in precise positions and retain these positions relative to one another when they are in motion.

Alternatively the two bands may be driven continuously at a suitable speed, and synchronised with one another. The axes of the rollers (61 , 62) are preferably vertical. The width of each band (63) is similar to but not

necessarily equal to the length of the tobacco portion of the cigarettes to be processed. The length of the bands between the drive and tail rollers is dependent upon the number of cigarettes to be processed simultaneously, as the device consists of several identical modules operating together in order to achieve the desired total throughput capacity. The outer surface of each band is provided with ribs (64) which project perpendicularly outwards for a distance approximately equal to the radius of the cigarettes being processed, and extend across the width of each band perpendicularly to the edges of the band. Referring to fig 10 which shows a partial plan view of the bands, the distance 'X' between the opposed surfaces of the bands is greater than the diameter of the cigarettes being processed. The inner surfaces of the bands are supported by plates or rails (65) which extend from the tail to the drive rollers and are tangential to those rollers. The bands are pre-tensioned sufficiently to ensure that their movement between the drive and tail rolls follows an essentially straight line.

The two band assemblies are positioned so that the ribs of one assembly face the ribs of the other, thus forming rectangular section pockets (67) into which cigarettes (66) can be inserted. When cigarettes whose radius is smaller than the projection of the ribs from the band are to be processed, the bands are brought together in such a way that the ribs overlap one another and the distance 'X' between them is reduced, (see fig 1 1 ).

The distance Y (fig 1 1 ) between the ribs in the conveying direction of the bands is selected so that the displacement of the belt during the time taken for a cigarette to pass into the pocket is less than the longitudinal clearance Y-D, where D is the cigarette diameter. In a typical example, if the cigarette length is 100mm, and the velocity with which it is fed is 4 metres per second, then the time required for the cigarette to enter the pocket is 0.025 seconds. If the linear speed of the belts is 0.15 metres per second, the belt displacement will be 3.75 mm. Therefore the distance Y must be at least D + 3.75 mm. If the cigarette diameter is 8mm then the distance between ribs must be at least 1 1 .75 mm.

Referring to fig 8 and 9, a cigarette is fed into the first pocket of a group of three pockets by means of a tubular channel or duct, and may fall by gravity or be propelled by pneumatic or other means. Having started to feed one cigarette, the next is retained by a holding device (58) within the duct such as a solenoid operated pin. The fall of the cigarette through the pocket is stopped by the end of the filter resting against a static surface (68) located on the opposite side of the bands from which the cigarettes are introduced. This surface is preferably adjustable vertically, so that the protrusion of the filter portion of the cigarette below the bands can be precisely determined. The movement of the bands transfers the cigarette to the next position where a hammer device (69) then impacts against the protruding filter and breaks it away from the tobacco rod portion of the cigarette, which remains in the pocket formed by the two ribbed bands. The filter is initially removed from its position by the hammer impact, and is further removed by suction, gravity, or a combination of these. The tobacco rod is prevented from falling out of the pocket by the presence of the hammer device. At the same time the next cigarette is fed to the now vacant first pocket position, and the two bands continue moving to the next position. When the tobacco rod of the first cigarette reaches the third position it falls from the pocket by gravity or is ejected by air jet or other mechanical means.

The following paragraphs relate to further aspects of the invention.

The further aspects of the present invention relate to a tobacco reclaim device.

In the cigarette manufacturing process, defective cigarettes are detected and rejected automatically, and then re-processed to recover and re-use their tobacco content. The process of reclaiming the tobacco depends on achieving an efficient separation of tobacco from the cigarette paper, which is used to enclose the tobacco, and the associated cigarette filter, while minimising any degradation or reduction of tobacco particle size.

Existing processes for achieving this separation include sieving, mechanical deformation and shock combined with air separation. Other methods of separation involve slitting the cigarette paper generally along the cigarettes' longitudinal axis, thus releasing the tobacco which can then be separated from the paper by sieving. These existing processes can be applied to achieve relatively good separation of paper and filters from tobacco. However, the introduction of more sophisticated filters containing encapsulated or granular flavour or filtration materials requires even higher levels of separation efficiency than can be achieved by these existing means. In accordance with the present invention, as seen from a further aspect, there is provided a cigarette processing assembly for processing cigarettes comprising a filter portion and a tobacco portion, to separate the filter portion from the respective tobacco portion, the assembly comprising:

a conveyor for conveying cigarettes;

alignment means for aligning the cigarettes with respect to the conveying means; a sensor for sensing an orientation of each of the cigarettes with respect to the conveyor; and,

a cutter for cutting the cigarette to separate the filter portion from the tobacco portion. Advantageously, the device separates the cigarette tobacco from the associated filter and thus ensures that the reclaimed tobacco is predominantly free from any of the constituents of the filter.

The conveyor may comprise a conveyor belt or a conveyor drum, and the alignment means preferably comprises a plurality of channels disposed upon a surface of the conveyor, which are arranged to separately receive a cigarette. The channels preferably comprise a plurality of corrugations, which preferably extend substantially transverse a conveying direction. Accordingly, as the cigarettes fall from a hopper or similar for example, onto the conveyor or drum, they are arranged to separately locate within a respective channel and become aligned across the conveyor.

Preferably, the sensor comprises at least one optical sensor disposed adjacent the conveyor for sensing the orientation of the cigarettes within the channels, to determine whether the cigarette filter portion extends proximate a first side or a second side of the conveyor.

Preferably, the assembly further comprises adjustment means for adjusting the position of the cigarettes on the conveyor in dependence of the sensed orientation of the cigarettes. The adjustment means preferably comprises at least one air jet for directing a jet of air toward the cigarettes to displace the cigarettes across the conveyor, namely along the respective channels. The adjustment means is arranged to displace the cigarettes so that the filter portion extends out of the respective channel. Preferably, the adjustment means further comprises a stop to limit the extent to which the cigarettes are displaced out from the respective channel. Preferably, the conveyor comprises holding means for holding the cigarettes upon the conveyor to prevent the cigarettes from falling from the conveyor or from otherwise becoming displaced upon the conveyor as the cigarettes are conveyed through the assembly. The holding means is arranged to hold the portion of the cigarette which extends within the channel and preferably comprises a plurality of apertures disposed within channels of the conveyor which are arranged in fluid communication with a pumping arrangement, for reducing the air pressure at the side of the surface opposite the side upon which the cigarettes are supported.

Preferably, the cutter comprises a rotating cutter having at least one blade which is arranged to extend to the side of the channels to cut the cigarettes and separate the filter portions from the respective tobacco portions.

The assembly preferably further comprises a cutting drum for cutting the tobacco portion, to release the tobacco therefrom.

In accordance with the present invention as seen from yet another aspect, there is provided a separation process for separating a cigarette tobacco portion from a cigarette filter portion, the process comprising:

- receiving cigarettes upon a conveyor;

- aligning the cigarettes upon the conveyor;

- sensing an orientation of each of the cigarettes upon the conveyor; and,

- cutting the cigarettes to separate the tobacco portion from the filter portion.

The process preferably further comprises holding the cigarettes upon the conveyor to minimise any displacement of the cigarettes upon the conveyor as they are conveyed. The process further comprises repositioning the cigarettes upon the conveyor in dependence of the sensed orientation of the cigarettes.

Following the cutting of the cigarettes, the process preferably further comprises cutting the tobacco portion to release the tobacco from a paper enclosure and subsequently releasing the cigarettes from the conveyor.

The process preferably further comprises separating the released tobacco from the enclosures.

An embodiment of the present invention will now be described by way of example only and with reference to the accompanying drawings in which:

Figure 12a is a schematic illustration of a side view of a screening conveyor of a cigarette processing assembly according to an embodiment of the present invention; Figure 12b is a plan view of the screening conveyor illustrated in figure 12a;

Figure 13 is a schematic illustration of the passage of cigarettes from a hopper onto a conveying drum of the assembly according to an embodiment of the present invention; Figure 14 is a plan view of the conveying drum of the assembly according to an embodiment of the present invention; and,

Figure 15 is a schematic illustration of the passage of cigarettes from a hopper onto a conveying drum of the assembly according to an embodiment of the present invention, further illustrating the position of the rotary cutting knives.

Referring to figure 12 of the drawings, waste cigarettes from the manufacturing process are fed into an initial screening vibratory conveyor to separate loose tobacco and overlength cigarettes from the single cigarettes. This initial screening conveyor consists of a perforated plate or mesh screen 20' of a suitable aperture size to allow the majority of loose tobacco to pass through to a collection tray and discharge chute 22' located underneath. A typical aperture size would be in the range of 2 to 4 mm, but need not necessarily be confined to this range as the selection of the sieve aperture would depend on the type of tobacco being processed. Following the sieve section the waste cigarettes pass to a second 2-deck vibratory conveying section whose top deck conveying surface 21 ' is corrugated in the longitudinal conveying direction. The dimensions of the corrugations are selected to be commensurate with the diameters of the cigarettes being processed, and would typically be in the form of V or U sections of between 6 and 10mm width, but not necessarily confined to this range. The purpose of the corrugations is to align the cigarettes so that over-length, deformed or double cigarettes can be separated from single cigarettes. This separation is achieved by slots in the bottoms of the U or V sections which are slightly longer than half the length of the cigarettes being processed. Only the standard length cigarettes are able to fall through the slots onto the lower deck conveying surface which is also formed from U or V corrugations similar to those of the top deck. The double length or over-length cigarette rods on the top deck will possibly also include deformed cigarettes and groups of cigarettes which have been stuck together. These items are all too large to pass through the slots onto the lower deck, and are collected as they fall from the end of the conveyor into a chute 23' to be processed separately.

The standard length cigarettes are transferred from the corrugated lower deck to a collection band conveyor 2' running at right angles to the separation conveyor's direction. This band conveyor has a corrugated surface. One or several rotating brushes and static deflectors assist the cigarettes to lie within the corrugations of the band conveyor, so that their axes are perpendicular to the conveying direction.

Referring to figure 13 of the drawings, at the end of the collection band 2', the cigarettes roll or fall down an inclined chute into a hopper 3' at the bottom of which there is a fluted rotating conveying drum 4'. The axis of this drum is parallel with the head-roll of the orienting band conveyor, and the flutes in the drum periphery are also parallel to the drum axis. Referring to figure 14 of the drawings, the axial length of the drum is equal to the length of the cigarettes plus the length of one filter, plus an additional small allowance for clearances and tolerances. The central portion of the drum 4' is fluted, and either side is plain 18', with its circumference coincident with the inner diameter or bottoms of the flutes. The flutes are generally of U section of similar but slightly greater width than the diameter of the cigarettes being processed. The bottoms of the U shaped flutes are provided with a plurality of small holes 17' which communicate with a plenum chamber within the drum. A pumping arrangement (not shown) is used to apply a vacuum is applied to this plenum by means of a suitable rotary union, which results in the cigarettes being held in the flutes by suction.

Referring to figures 13 and 14 of the drawings, as the drum rotates, the end of each cigarette passes an electro-optical inspection station 5' which provides a signal according to whether the tobacco or filter is being viewed. To avoid the possibility of incorrect identification due to the tobacco being obscured by paper, the cigarettes are viewed from both ends. Control logic initiates a high speed pulse of compressed air 6' to move individual cigarettes to one side or the other of the fluted drum. The precise position of these cigarettes is determined by end datum plates 16' whose positions can be adjusted according to the length of the filters in the cigarettes being processed. This process may take place over one or more segments of the fluted drum, using one or more sets of compressed air jets 6' operated by control logic which determines whether an individual cigarette has to be moved to one side or other of the drum. Referring to figure 15, cigarettes originally with their filters in position A' will be moved to position C by the action of the air jets 6', and those originally in position B' will be similarly aligned in position D'.

The cigarettes then pass to a cutting station 7' at which rapidly rotating rotary blades or knives cut the cigarette transversely, thus separating the filters from the cigarette. The dimensional alignment of the cigarettes is such that the knives cut through the tobacco portion of the cigarette and not the filter, thus eliminating the possibility of contamination of the reclaimed tobacco by filter material.

The tobacco portion of the cigarette is held by the central portion of the fluted drum 4', and the filters are supported by the two outer parts of the drum surface. As the outer plain parts of the drum surface are not provided with vacuum holes, the filters can fall away naturally by gravity into a collection chute 8' into a receptacle 9'. If necessary, the ejection of the filters from the drum can be assisted by compressed air. Referring to figure 13 of the drawings, the tobacco portion of the cigarette can be released from the drum by locally releasing the vacuum and/or using compressed air jets to assist removal of the cigarette from the drum. These portions of the cigarette can then be processed in a conventional cigarette reclaim plant. Alternatively they can be retained on the fluted drum 4' or transferred to a second fluted drum to allow the paper to be slit longitudinally.

Referring to figure 15 of the drawings, longitudinal slitting of the cigarette paper may be achieved by a cutting drum 10' which is provided with one or more radial knives disposed around its periphery. The cutting drum is in close proximity to the drum 4' on which the cigarettes are held, and its speed is synchronised with that drum. The knives press into the cigarettes typically for a distance of typically 1 mm or 2 mm to generate sufficient force to cut the paper.

The cut cigarettes which now each consist of a strip of paper and loose tobacco are ejected from the fluted drum by locally releasing the vacuum or by applying external suction 1 1 '. This may typically but not exclusively be applied by means of a fan 12' and the mixed paper and tobacco separated from the air by means of a cyclone 14'. This material is then passed over a vibratory sieving conveyor 15' whose mesh aperture size is between 2 and 6mm but not confined to this range. The reclaimed tobacco falls through the mesh with virtually zero contamination by filter material or paper, and is collected in convenient receptacles from the lower deck of the sieving conveyor. The paper remains on the upper sieve deck and can be similarly collected or conveyed for example pneumatically to a waste compactor.

The following clauses are useful for understanding the further aspects of the invention:

1. A cigarette processing assembly for processing cigarettes comprising a filter portion and a tobacco portion, to separate the filter portion from the respective tobacco portion, the assembly comprising:

a conveyor for conveying cigarettes;

a cutter for cutting the cigarette to separate the filter portion from the tobacco portion. 2. A cigarette processing assembly according to clause 1 , wherein the conveyor comprises a conveyor belt or a drum. 3. A cigarette processing assembly according to clause 1 or 2, wherein the alignment means comprises a plurality of channels disposed upon a surface of the conveyor, which are arranged to separately receive a cigarette.

4. A cigarette processing assembly according to clause 3, wherein the channels comprise a plurality of corrugations, which preferably extend substantially transverse a conveying direction.

5. A cigarette processing assembly according to clause 3 or 4, wherein the sensor comprises at least one optical sensor disposed adjacent the conveyor for sensing the orientation of the cigarettes within the channels, to determine whether the cigarette filter portion extends proximate a first side or a second side of the conveyor.

6. A cigarette processing assembly according to any of clauses 3 to 5, further comprising adjustment means for adjusting the position of the cigarettes on the conveyor in dependence of the sensed orientation of the cigarettes, so that the filter portion extends out of the respective channel.

7. A cigarette processing assembly according to clause 6, wherein the adjustment means comprises at least one air jet for directing a jet of air toward the cigarettes to displace the cigarettes across the conveyor.

8. A cigarette processing assembly according to clause 7, wherein the adjustment means is arranged to displace the cigarettes so that the filter portion extends out of the respective channel.

9. A cigarette processing assembly according to any of clauses 6 to 8 wherein the adjustment means comprises or further comprises a stop to limit the extent to which the cigarettes are displaced out from the respective channel.

10. A cigarette processing assembly according to any preceding clause, wherein the conveyor comprises holding means for holding the cigarettes upon the conveyor to prevent the cigarettes from falling from the conveyor or from otherwise becoming displaced upon the conveyor as the cigarettes are conveyed through the assembly.

1 1. A cigarette processing assembly according to clause 10, as appended to any of clauses 3 to 9, wherein the holding means is arranged to hold the portion of the cigarette which extends within the channel.

12. A cigarette processing assembly according to clause 10 or 1 1 , as appended to any of clauses 3 to 9, wherein the holding means comprises a plurality of apertures disposed within channels of the conveyor which are arranged in fluid communication with a pumping arrangement, for reducing the air pressure at the side of the surface opposite the side upon which the cigarettes are received.

13. A cigarette processing assembly according to clause 3, wherein the cutter comprises a rotating cutter having at least one blade which is arranged to extend to the side of the channels to cut the cigarettes and separate the filter portions from the respective tobacco portions.

14. A cigarette processing assembly according to any preceding clause, further comprising a cutting drum for cutting the tobacco portion, to release the tobacco therefrom.

15. A separation process for separating a cigarette tobacco portion from a cigarette filter portion, the process comprising:

- receiving cigarettes upon a conveyor;

- aligning the cigarettes upon the conveyor;

- sensing an orientation of each of the cigarettes upon the conveyor; and,

16. A process according to clause 15, further comprising holding the cigarettes upon the conveyor to minimise any displacement of the cigarettes upon the conveyor as they are conveyed.

17. A process according to clause 15 or 16, further comprising repositioning the cigarettes upon the conveyor in dependence of the sensed orientation of the cigarettes.

18. A process according to any of clauses 15 to 17, further comprising cutting the tobacco portion to release the tobacco from a paper enclosure.

19. A process according to any of clauses 15 to 18, further comprising separating the tobacco from the enclosure.

Claims

1 . An apparatus for breaking down cigarettes to separate the filter portion from the tobacco portion, the apparatus comprising:

a conveying duct for conveying a cigarette in an orientation such that the longitudinal axes of the cigarette and the conveying duct are substantially in alignment;

cigarette-accommodating means comprising at least one channel, the channel being configured to accommodate a cigarette, such that the longitudinal axes of the cigarette and the channel are substantially in alignment;

means for lining up the channel with the conveying duct, to allow a cigarette to be delivered from the conveying duct to the channel;

the apparatus further comprising a stopping surface adjacent to the cigarette-accommodating means, the stopping surface being arranged to support a cigarette such that the cigarette remains partly accommodated within the channel;

the stopping surface being positioned such that when the cigarette is partly accommodated within the channel and supported against the stopping surface, the filter portion of the cigarette protrudes from the cigarette- accommodating means;

the apparatus further comprising separation means for separating the protruding filter portion from the tobacco portion.

2. An apparatus according to claim 1 , wherein the separation means comprises a knife.

3. An apparatus according to claim 1 , wherein the separation means comprises an anvil for separating the protruding filter portion from the tobacco portion through mechanical impact.

4. Apparatus according to any one of the preceding claims, wherein the means for lining up the channel with the conveying duct is further configured to move the protruding filter portion into contact with the separation means.

5. An apparatus according to any one of the preceding claims, wherein the cigarette-accommodating means comprises a drum that is rotatable about its longitudinal axis; and further wherein the means for lining up the channel with the conveying duct comprises means for rotating the drum about its longitudinal axis.

6. An apparatus according to claim 5, wherein the protruding filter portion is brought into contact with the separation means through rotation of the drum about its longitudinal axis.

7. An apparatus according to claim 5 or claim 6, wherein the longitudinal axis of the drum is substantially aligned with the longitudinal axis of the channel.

8. An apparatus according to claim 6, wherein the channel extends radially from the longitudinal axis of the drum.

9. An apparatus according to claim 8, comprising at least one further conveying duct and at least one further drum, the at least one further conveying duct being adapted to deliver cigarettes to the at least one further drum, wherein the longitudinal axes of the drum and the further drum coincide.

10. Apparatus according to any one of claims 1 -4, wherein the cigarette- accommodating means comprises a conveyor belt, the conveyor belt including a band supported between two posts, the channel being provided on an outer surface of the band and extending across the width of the band.

1 1 . Apparatus according to any one of claims 1 -4, wherein the cigarette- accommodating means comprises two conveyor belts, each conveyor belt including a band supported between two posts so as to define two longitudinal faces of the band, the conveyor belts being arranged such that a longitudinal face of one band is opposed to a longitudinal face of the other band;

the outer surfaces of the bands each being provided with a plurality of ridges, the ridges each extending across the width of the respective band; such that the channel of the cigarette-accommodating means is defined by a group of the ridges distributed on opposed longitudinal faces of the bands.

12. Apparatus according to claim 1 1 , wherein the separation of adjacent ridges on one band is at least 10mm.

13. An apparatus according to any one of the preceding claims, wherein the conveying duct and the drum are arranged such that the cigarette is delivered to the channel under the action of gravity.

14. An apparatus according to any one of the preceding claims, further comprising transport means for transporting the cigarette along a path to the conveying duct.

15. An apparatus according to claim 14, further comprising one or more guide walls located above the transport means, the guide walls being arranged to guide the orientation of the cigarette such that the longitudinal axis of the cigarette is substantially aligned with the direction of travel of the transport means.

16. An apparatus according to claim 14 or claim 15, wherein the transport means is provided with a sensor to determine whether the cigarette is travelling with the tobacco portion or the filter portion foremost.

17. An apparatus according to any one of the preceding claims, further comprising means for ensuring that cigarettes delivered into the conveying duct have their filter portion travelling foremost.

18. An apparatus according to claim 17, wherein the cigarette- accommodating means is a drum, the longitudinal axis of the drum is substantially aligned with the longitudinal axis of the channel, and the separation means and stopping surface are both on the same side of the drum.

19. An apparatus according to claim 17, wherein the cigarette- accommodating means is a drum, the channel extends radially from the longitudinal axis of the drum, and the drum comprises an internal passage for delivering the cigarette to a further channel provided in a radially opposite part of the drum.

20. An apparatus according to any one of claims 1 -9 and 13-16, further comprising means for for ensuring that cigarettes delivered into the conveying duct have their tobacco portion travelling foremost.

21 . An apparatus according to claim 20, wherein the cigarette- accommodating means is a drum, the longitudinal axis of the drum is substantially aligned with the longitudinal axis of the channel, and the drum lies between the separation means and the stopping surface.

22. An apparatus according to claim 21 , wherein the cigarette- accommodating means is a drum, the channel extends radially from the longitudinal axis of the drum, and the drum is adapted to deliver the cigarette to the stopping surface through rotation about the longitudinal axis of the drum.

23. An apparatus according to any one of the preceding claims, further comprising means for confirming the presence of a cigarette supported against the stopping surface, prior to separation of the filter portion from the tobacco portion.

24. Apparatus according to any one of the preceding claims, wherein the distance between the stopping surface and the cigarette-accommodating means is in the range 5-40mm, preferably 7-35 mm, more preferably 15- 35mm.

25. Apparatus according to any one of the preceding claims, wherein the diameter of the conveying duct is in the range 5-30mm, preferably 7-20mm.

26. Apparatus according to any one of the preceding claims, wherein the diameter of the channel is in the range 5-20mm, preferably 7-20mm.

27. A method of breaking down cigarettes to separate the filter portion from the tobacco portion, the method comprising providing an apparatus according to any one of the preceding claims;

entering a cigarette into the conveying duct;

lining up the channel with the conveying duct to receive a cigarette from the conveying duct;

causing the cigarette to pass into the channel and become supported against the stopping surface; and causing the separation means to separate the protruding filter portion from the tobacco portion.

28. Method according to claim 27, further comprising the step of moving the channel to bring the cigarette into contact with the separation means.

29. An apparatus for moving an object past a sensor at a pre-determined speed, the apparatus comprising

two guiding walls for guiding the passage of the object towards the sensor,

a conveyor belt providing a support surface for supporting the object and moving the object along the path defined by the guiding walls;

a driving surface opposed to the support surface of the conveyor belt, the driving surface having a speed that is matched to that of the support surface, the driving surface assisting in moving the object along the path defined by the guiding walls.

30. An apparatus according to claim 29, wherein the driving surface is provided by a driving wheel.

31 . Apparatus for accommodating an elongate object and moving the elongate object in a lateral direction of said object, the apparatus comprising: two conveyor belts, each conveyor belt including a band supported between two posts so as to define two longitudinal faces of the band, the conveyor belts being arranged such that a longitudinal face of one band is opposed to a longitudinal face of the other band;

the outer surfaces of the bands each being provided with a plurality of ridges, the ridges each extending across the width of the respective band; such that a group of the ridges distributed on opposed longitudinal faces of the bands defines a channel therebetween for accommodating the elongate object.