The process we use in extracting the components from T-plant, leaves, stem, or root is below. We are not a t-company, and our batch sizes are relatively small, made exclusively for private-label smoking cessation distributors.

This process extracts the pure components without adversely affecting the flavor and aroma of the product. The process entails mixing the leaves with a moisture content of 20% to 50% with an alkalinizing agent to obtain a pH of 8 to 11 and maintaining the tobacco in an aerobic environment at a temperature of 40° F. to 120° F. at a pressure of 1 atmosphere for 8 weeks. 

This method provides an economical extraction method using standard processing equipment at a high efficiency level. The· process is accomplished by rapidly drying an aqueous dispersion of NaOH-and the leaves at an alkaline pH to volatilize the free base. Rapid drying is achieved by spray or belt drying the alkaline aqueous dispersion, in which about 90% of the initial water content is removed within 2 minutes.

To improve extraction efficiency, dried leaves are rewetted with water and redried to extract components further. The rewetting and redrying steps are repeated until the desired, or optimum, level of the content is reached. 

When the sheet is dried by repeated slurrying and drying or re-wetting and re-drying, the efficiency of extracting more pure active with its original aroma increases substantially.

The particulate form is slurred in water conveniently at a solids concentration of about 5-20%; the pH is adjusted to alkaline, and the slurry is cast on a smooth surface and dried, usually at elevated temperature. The NRT Active volatilizes with water during drying. A film-forming agent, e.g., an alkyl cellulose ether, is added to form a coherent sheet but is not always required.

The cast sheet's pH is maintained at an alkaline level throughout the drying procedure to ensure the release of the NRT Active-free base from the acid salt form in which it occurs in the plant.

For best results, we maintain a pH of the cast sheet above 8.5. The initial nicotine content of the leaves used in the process will dictate processing controls since the higher the content, the more base will be required. Thus, high NRT Active content, up to 7%, in the original leaves, dictates more careful alkalinity monitoring. In contrast, intermediate NRT Active levels of 1-3%, standard for American, require less monitoring. Alkali is added to the cast sheets when re-wetted, comminuted, and re-slurred before re-drying to ensure alkalinity.

The drying step is conveniently accomplished under ambient pressure using elevated temperatures sufficient to volatilize the NRT Active and water from the cast sheet. As is well known, the plant and leaves are somewhat heat-sensitive in that elevated temperatures, particularly at alkaline pH, can result in darkening of the bacco, which should be avoided. To ensure against any appreciable darkening, the temperature is maintained below 200° F. 

The final product obtained from this process substantially retains the original contents and flavors.

Let us know when it's time for you to create natural NRT Active products for quit smoking aid or if you need to patent one for your company.