CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority from U.S. Provisional Patent Application 63/292,375 filed on December 21 , 2021 and incorporated by reference herein.

TECHNICAL FIELD

[0002] This application generally relates to methods of manufacturing cannabis-based consumer products and, more specifically, to methods of manufacturing cannabis pre-rolls at an industrial scale.

BACKGROUND

[0003] Upon stage-wise legalization of cannabis-based consumer products in Canada and eventually in various other areas in the world, industrial scale production and accessibility to a wide variety of forms of cannabis have accelerated to fulfill emerging demands.

[0004] Although there are different methods of consuming cannabis-based consumer products (e.g., oral ingestion, topical administration orvaping the cannabis oil), smoking is still the preferred mode of consuming cannabis. Typically, cannabis material is reduced to a particulate form and loaded into a rolling medium (typically a rolling tube, cone, or wrapping paper) to obtain a cannabis pre-roll. The pre-roll is then lit and resulting smoke is inhaled by the user.

[0005] Reducing the cannabis material to particles often occurs in an industrial setting by milling. Milling cannabis and then loading it into a rolling medium can result in a mixture of particles that is not uniform and with a wide range of particle sizes (e.g., an undesirable particle size distribution). Such a non-uniform mix of particles, when wrapped as a smokable pre-roll, will not burn consistently due to voids and porosities created along the length of the wrapped cannabis material, resulting in an undesirable burn profile. Processed cannabis material with a relatively restricted range of particle sizes is preferable to obtain proper pre-roll density. However, the particle size distribution should not include a large fraction of fine or small particles; using an excess of fine particles (e.g., less than 1 mm size) results in overly compact pre-rolls that have reduced airflow. [0006] Cannabis trichomes are extremely sensitive to falling off the buds when the buds are processed, e.g., by milling or fractionating. Trichomes range in size from as little as 10 microns (0.01 mm) to about 500 microns (0.5 mm), so the falling off of the trichomes creates powder and fines when producing milled input for cannabis pre-roll filing. Trichomes are key to achieving potency in smokable products so their loss by removal from the remaining plant material also reduces potency of the resulting pre-roll.

[0007] Shredders have been used for destruction and disposal of cannabis waste, which may be regulated in some jurisdictions.

[0008] Considering the above, it would be desirable to be provided with a system or method that would at least partially alleviate the disadvantages of the existing technologies and cannabis manufacturing having improved characteristics.

SUMMARY

[0009] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key aspects or essential aspects of the claimed subject matter.

[0010] The methods described herein are for manufacturing cannabis pre-rolls by creating cannabis particles with particle sizes that when loaded into a rolling medium (typically a rolling tube, cone, or wrapping paper) result in a product having minimal porosity (e.g., with minimal void spaces through which air or liquid can pass between the solids). Accordingly, the methods disclosed herein can provide more consistent and controllable burning rate, more consistent and visually attractive products, and overall predictable and standardized user experience.

[0011] The methods disclosed herein describe cannabis flower processing that reduces trichome detachment from the cannabis plant material. For example, processing cannabis plant material in plural machining steps with different machines, such as by first shredding the cannabis plant material into shredded pieces with a shredding machine (e.g., a low-impact shredder) and then milling the shredded pieces into particles with a milling machine, may be useful to preserve or maintain high levels of trichomes. The processing methods use milling techniques with low impact forces that tend to minimize trichome detachment. The combined low-impact shredding and milling technique reduces the time and forces required in the milling stage, reducing the buds to a consistent size without creating fines, and with more than 60% of the resulting particles falling in a desired size range (e.g., between 1.4 - 2.0 mm).

[0012] Broadly stated, in some embodiments, the present disclosure relates to methods of manufacturing a cannabis pre-roll comprising a) providing a cannabis material in particle form comprising < 40 wt.% of particles having a size < 0.425 mm, and b) incorporating the cannabis material into a rolling medium to form the cannabis pre-roll.

[0013] Implementations can include one or more of the following features: the rolling medium is a pre-roll tube or cone. The cannabis material in particle form comprises < 10 wt.% of particles having a size of < 0.425 mm. The cannabis material in particle form comprises < 5 wt.% of particles having a size of < 0.425 mm. The cannabis material in particle form further comprises at least 50 wt.% of particles having a size above 2.0 mm. Step b) comprises packing the cannabis material into the rolling medium with a packing pressure of from about 40 psi to about 120 psi. The packing pressure is of about 85 psi. The packing pressure is obtained with an automated tamper configured for insertion in the rolling medium.

[0014] In some embodiments, the present disclosure relates to methods of manufacturing a cannabis pre-roll comprising a) providing cannabis material in the form of dried cannabis flowers, b) shredding the dried cannabis flowers into pieces, c) milling the pieces into cannabis particles, and d) incorporating the cannabis material into a rolling medium to form the cannabis pre-roll.

[0015] Implementations can include one or more of the following features: shredding the dried cannabis flowers into pieces having a size of up to about 20 mm; shredding the dried cannabis flowers into pieces having a size of between about 4 mm and about 20 mm; milling the pieces into cannabis particles having < 20 wt.% of particles having a size < 1.0 mm; milling the pieces into cannabis particles having < 10 wt.% of particles having a size < 1.0 mm. Shredding the dried cannabis flowers into pieces having a size from about 7 mm to about 10 mm.

[0016] In some embodiments, the present disclosure relates to cannabis plant material compositions in particle form comprising a particle size distribution (PSD) of cannabis particles having < 40 wt.% of particles having a size < 0.425 mm. Implementations can include one or more of the following features: a PSD of cannabis particles having < 20 wt.% of particles having a size < 0.425, a PSD of cannabis particles having < 20 wt.% of particles having a size < 1mm, or a PSD of cannabis particles having < 10 wt.% of particles having a size < 1.0 mm. [0017] In some embodiments, the present disclosure relates to smoking articles comprising cannabis plant material in particle form comprising a particle size distribution (PSD) of cannabis particles having < 40 wt.% of particles having a size < 0.425 mm.

[0018] Implementations can include one or more of the following features: a PSD of cannabis particles having < 20 wt.% of particles having a size < 0.425, a PSD of cannabis particles having < 20 wt.% of particles having a size < 1mm, or a PSD of cannabis particles having < 10 wt.% of particles having a size < 1.0 mm. The articles is a cannabis pre-roll comprising the cannabis material loaded into a rolling medium. It has a form of a tube or a cone. It has a has a burn test pass rate of at least 0.6, or at least 0.75.

[0019] In some embodiments, the present disclosure relates to a cannabis plant material composition in particle form, comprising cannabis particles wherein more than 60 wt.% of the cannabis particles constituting the cannabis plant material composition have a size between 1.4 mm and 2.0 mm.

[0020] In some embodiments, the present disclosure relates to a smoking article comprising cannabis plant material in particle form, comprising cannabis particles wherein more than 60 wt.% of the cannabis particles of the smoking article have a size between 1.4 mm and 2.0 mm.

Definitions

[0021] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by a person of ordinary skill in the art to which the present invention pertains. As used herein, and unless stated otherwise or required otherwise by context, each of the following terms shall have the definition set forth below.

[0022] As used herein, the term “Cannabis” generally refers to a genus of flowering plants that includes a number of species. There are three different species that have been recognized, namely Cannabis sativa, Cannabis indica and Cannabis ruderalis. Hemp, or industrial hemp, is a strain of the Cannabis sativa plant species that is grown specifically for the industrial uses of its derived products. Hemp has lower concentrations of the cannabinoid tetrahydrocannabinol (THC) and higher concentrations of the cannabinoid cannabidiol (CBD), which decreases or eliminates its psychoactive effects.

[0023] As used herein, the term “cannabis plant(s)”, encompasses wild type Cannabis and also variants thereof, including cannabis chemovars (or “strains”) that naturally contain different amounts of the individual cannabinoids. For example, some Cannabis strains have been bred to produce minimal levels of THC, the principal psychoactive constituent responsible for the high associated with it and other strains have been selectively bred to produce high levels of THC and other psychoactive cannabinoids. Cannabis plants produce a unique family of terpeno-phenolic compounds called cannabinoids. There are 483 identifiable chemical constituents known to exist in the cannabis plant, and at least 85 different cannabinoids have been isolated from the plant. The two cannabinoids usually produced in greatest abundance are CBD and/or A9-THC, but only THC is psychoactive. Cannabis plants are categorized by their chemical phenotype or “chemotype,” based on the overall amount of THC produced, and on the ratio of THC to CBD. Although the overall cannabinoid production is influenced by environmental factors, the THC/CBD ratio is genetically determined and remains fixed throughout the life of a plant. Some plants produce relatively low levels of THC and high levels of CBD (sometimes referred to as “non-drug” plants), while some plants produce high levels of THC and low levels of CBD (sometimes referred to as “drug” plants).

[0024] As used herein, the term “terpenes” generally refers to refer to a class of chemical components comprised of the fundamental building block of isoprene, which can be linked to form linear structures or rings.

[0025] The term “flavonoid” as used herein refers to a group of phytonutrients comprising a polyphenolic structure. Flavonoids are found in diverse types of plants and are responsible for a wide range of functions, including imparting pigment to petals, leaves, and fruit. Any suitable flavonoid may be used in the cannabis product of the present invention. For example, flavonoids originating from a cannabis plant may be used, including but not limited to: apigenin, cannflavin A, cannflavin B, cannflavin C, chrysoeril, cosmosiin, flavocannabiside, homoorientin, kaempferol, luteolin, myricetin, orientin, quercetin, vitexin, and isovitexin.

[0026] As used herein, the term “cannabis trim” generally refers to excess leaves a cultivator trims from their plants. There are two types of leaves that are trimmed from cannabis buds, sugar leaves, which are smaller one-fingered leaves close to the bud, fan leaves, which are larger multifingered leaves. Cannabis trimming can occur either before or after harvest of the plants. If done before, the trimming process maximizes the cannabis plant’s bloom and, in turn, yielding more desirable crystals. A good trim will get the grower a bigger, higher quality plant yield. If trimming is carried out post-harvest, the appearance and odor of the buds are improved, and the lower leaf quantity makes the resulting plant matter “smoother” to smoke or vaporize. [0027] As used herein, the term “additive” means a composition or component other than cannabis material. In the context of the present disclosure, the additive may be any suitable nontoxic additive known in the art, such as tobacco leaves, burn enhancers, one or more cannabinoids (in the form of crude extract, distillate, isolate, winterized cannabis extract, kief, hashish or any combinations thereof), terpenes, or any combination thereof. Other non-toxic additives such as natural colourants may also be included. Additives may be added to alter the characteristics of the cannabis pre-roll, such as cannabinoid content, potency, entourage effect, odor, color, and the like.

[0028] All features of exemplary embodiments which are described in this disclosure and are not mutually exclusive can be combined with one another. Elements of one embodiment can be utilized in the other embodiments without further mention. Other aspects and features of the present invention will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments in conjunction with the accompanying Figures.

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] A detailed description of specific exemplary embodiments is provided herein below with reference to the accompanying drawings in which:

[0030] FIG. 1 is a non-limiting flowchart of a method for manufacturing a cannabis pre-roll.

[0031] FIG. 2 is a non-limiting flowchart of a method for obtaining cannabis particles.

[0032] FIG. 3 is a non-limiting flowchart of a method for incorporating the cannabis material obtained using the method of FIG. 2 into a rolling medium.

[0033] FIG. 4 is a variant of the method illustrated in FIG. 3.

[0034] FIG. 5 is another variant of the method illustrated in FIG. 3.

[0035] FIGS. 6A-6D are graphs showing particle size distributions of cannabis particles obtained following different processing methods.

[0036] In the drawings, exemplary embodiments are illustrated by way of example. It is to be expressly understood that the description and drawings are only for the purpose of illustrating certain embodiments and are an aid for understanding. They are not intended to be a definition of the limits of the invention. DETAILED DESCRIPTION

[0037] A detailed description of one or more embodiments of the invention is provided below along with accompanying figures that illustrate the principles of the invention. The invention is described in connection with such embodiments, but the invention is not limited to any embodiment. The scope of the invention is limited only by the claims. Numerous specific details are set forth in the following description to provide a thorough understanding of the invention. These details are provided for the purpose of non-limiting examples and the invention may be practiced according to the claims without some or all of these specific details. For sake of clarity, technical material that is known in the technical fields related to the invention has not been described in detail so that the invention is not unnecessarily obscured.

[0038] The methods described herein are for manufacturing cannabis pre-rolls by creating cannabis particles with particle sizes that when loaded into a rolling medium (typically a rolling tube, cone, or wrapping paper) result in a product having minimal porosity (e.g., with minimal void spaces through which air or liquid can pass between the solids) and minimal incorporation of dust and loose trichomes. Accordingly, the methods disclosed herein can provide more consistent and controllable burning rate, more consistent and visually attractive products, and overall predictable and standardized user experience.

Overview of manufacturing cannabis pre-rolls

[0039] FIG. 1 is a non-limiting flowchart of a process 10 of making cannabis pre-rolls in accordance with an embodiment of the present disclosure. The process 10 includes a step 100 of providing a mixture of cannabis material in particle form.

[0040] At step 180 a predetermined weight of the mixture of cannabis material is incorporated in a rolling medium to form the cannabis pre-rolls. For example, a weight selected in the range of from about 0.1 g to about 2.5 g (including any value therein, such as about 0.2 g, 0.5 g, 1.0 g, 1.2 g, 1.5 g, 1.8 g, etc.) of the mixture of cannabis material can be incorporated into the rolling medium, or other weight values can be used if desired. Cones or tubes are non-limiting examples of rolling medium for containing the cannabis particles. Cones mimic a funnel, with a larger opening for packing and a smaller opening for inhaling, allowing for a different type of air flow than a tube. A tube, on the other hand, has substantially the same diameter on the opening as it does on the mouthpiece, which mimics the pre-roll type of air flow. The rolling medium can be a preroll tube or cone, for example having a length of from about 50 mm to about 300 mm (including any value therein, such as about 55 mm, 60 mm, 65 mm, 70 mm, 75 mm, 80 mm, 85 mm, 90 mm, 95 mm, 100 mm, 105 mm, 110 mm, 115 mm, 120 mm, etc.). The rolling medium can be made with rolling paper, hemp, cordia palm leaf, tendu leaf, flower petal, banana leaves, flax, sisal, rice straw, esparto, and the like, and may be transparent, colored and/or flavored. The rolling medium may also further include an additive on one of its surfaces (internal or external), such as kief, terpenes, distillate, isolate, cannabis oil, or kief.

[0041] In some embodiments, the rolling medium has a high filler content and a basis weight of 10-28 g/m ² . To control the smoking properties, the rolling medium may have a porosity to allow ventilation of the burning ember or contain materials that control the burning rate of the cannabis pre-roll and stability of the produced pre-roll residues. In some embodiments, the rolling medium is suited to the type of cannabis particles and contains additives that regulate burning. Among the fillers that can be used are calcium carbonate to influence the permeability and color, magnesium carbonate to improve ash color, or titanium oxide if a particularly white ash is required. Sodium potassium tartrate, sodium and potassium citrate can be used as a combustion regulator in rolling medium.

Manufacturing cannabis particles

[0042] FIG. 2 describes further details of step 100 shown in FIG. 1. To provide the mixture of cannabis material in particle form, dried cannabis flowers are provided at step 110. The dried cannabis flowers can be provided from raw cannabis plant material that has been processed by removing plant stems and other material from the dried buds. In addition to plant stems, stalks, fan leaves, and other possible waste will have been removed from the overall plant material. In preferred embodiments described herein, primarily cannabis flowers (also described as buds) are processed at step 110. In some embodiments, other plant material such as cannabis trim, stems, stalks, or other types of plants are processed at step 110 instead of or in addition to buds.

[0043] The dried cannabis buds with stems and other cannabis plant material removed that are provided at step 110 are shredded in step 120 to render the dried cannabis flowers into pieces. The shredding action occurs using a low impact, low RPM shredder. For example, an Industrial Monster™ shredder available from JWC Environmental® (Santa Ana, California) can be used. Such a shredder has a grinding action that cuts the plant material placed therein without impact. Accordingly, the cannabis buds that is shredded at step 120 is not pulverized; due to the smoother, less violent action of the shredding action, the small sized trichomes present on the plant material are subject to fewer forces tending to remove them from the plant material to which they are attached. The resulting flower pieces achieve a more consistent particle size, with less powder and fine particles (e.g., particles having an average size of 0.25 mm or 250 microns) present in the pieces post shredding. In some instances, the shredding of step 120 reduces the cannabis flowers to pieces of about 4 mm to about 20 mm, e.g., in some cases about 4 mm to about 10 mm in size, or in some cases about 7 mm to about 10 mm in size.

[0044] The cannabis pieces obtained by shredding in step 120 are milled at step 130 to obtain cannabis in particulate form, or cannabis particles. Milling can be performed via any method available in the art to breakdown cannabis plant material into particle form. For example, a Mobius M210 Mill™ available from Mobius (Surrey, British Columbia) can be used. During step 130, the cannabis flowers can be milled into cannabis particles form with a wide range of sizes, typically from 0.05 mm to 6.0 mm (see, for example the PSD in Fig. 6B). In some embodiments, step 130 results in cannabis particles of between about 1.4 mm - 2.0 mm.

[0045] In some embodiments, additives are added into the mixture at optional step 160. The additives can be added before or during step 130 or at any other step in step 100 (as shown in FIG. 2) or in process 10.

[0046] Generally, in some embodiments, step 130 of milling the pre-shredded flowers results in particles having (1) a first amount of particles with a particle size indicating a relatively large size, e.g., above 2.0 mm, (2) a second amount of medium-sized particles sized from above 0.425 mm to 2.0 mm and (3) a third amount of particles that are small, with a size of < 0.425 mm.

[0047] For example, the shredded and milled cannabis flowers are processed to include large particles having a particle size of above 2.0 mm that account for about 75 wt.% of particles, e.g., from about 50 wt.% to about 90 wt.% being particles above 2.0 mm. The cannabis particles can also include medium-sized particles such that approximately 20 wt.% of particles have a size of from above 0.425 to 2.0 mm, e.g., about 10 wt.% to about 40 wt.% of particles having a size of from above 0.425 to 2.0 mm. The mixed cannabis material can include smaller particles such that less than 10 wt.% or approximately 5 wt.% of particles have a size of < 0.425 mm e.g., about 4 wt.% to about 8 wt.% of particles.

[0048] For example, the shredded and milled cannabis flowers are processed to include relatively small particles having a size of less than 1.0 mm that accounts for < 20 wt.% of the particles, e.g., less than 10 wt.%. In some embodiments, the shredded and milled cannabis flowers are processed to include relatively small particles having a size of < 0.425 mm that account for < 40 wt.% of the particles, e.g., less than 10 wt.%.

Creating the cannabis pre-rolls

[0049] FIG. 3 illustrates method details of step 180 in FIG. 1 for incorporating the cannabis particles obtained from step 130 of FIG. 2 into a rolling medium. The method entails filling a rolling medium (such as a rolling paper, tube or cone, for example a pre-roll tube or cone) with cannabis particles 190. The filling step can be done manually or done semi-automatically or automatically with rolling medium sequentially filled via a filling apparatus (e.g., a hopper). Following step 190, at optional step 220 the rolling medium filled with cannabis particles can be closed at one end thereof (or at both ends thereof, in some implementations) to immobilize the mixture into the rolling medium, thereby forming a cannabis pre-roll. The immobilized mixture may take the form of a rod in the rolling medium. In some embodiments, the rolling medium may be filled with a mixture including the cannabis particles as well as other components, such as tobacco leaves or other additives (e.g., burning additives, cannabis distillate, terpenes, flavonoids, etc.).

[0050] Optional step 220 of closing the one end (or opposite ends) of the rolling medium can be carried out on a rolling tube or cone or wrapping paper with an upper portion defining an upper aperture through which the cannabis particles is incorporated. The upper portion can be joined to close off the upper aperture. The joining can occur by twisting the upper portion along a longitudinal axis of the rolling medium. In some embodiments step 220 is omitted, and the ends of the filled rolling medium are not closed.

[0051] FIG. 4 shows to another embodiment for method step 180’ for incorporating the cannabis particles into the rolling medium. To achieve optimal porosity of the mixed cannabis material across the length of the resulting cannabis pre-roll, the cannabis particles (and any other added additives) may be further densified at step 200. Densification can be achieved by applying pressure (called packing pressure) on the cannabis particles that is incorporated into the rolling medium. In some embodiments, the pressure is applied on the cannabis particles once the cannabis particles entirely fill the rolling medium. In other embodiments, only a fraction of the rolling medium is filled with cannabis particles and the pressure is subsequently applied to densify the fraction. This procedure is repeated until the entire rolling medium is filled with the cannabis particles. The packing pressure could be from about 40 psi to about 120 psi, or from about 50 psi to about 110 psi, or from 60 psi to about 100 psi, or from about 70 psi to about 90 psi, or about 85 psi, for example.

[0052] FIG. 5 shows another embodiment of method step 180” for incorporating the cannabis particles into the rolling medium. Before filling the rolling medium with cannabis particles (and any other added additives) in step 190, a filter is added at one end of the rolling medium at step 210 to filter part of the smoke chemicals formed upon smoking the cannabis pre-roll. Step 210 can include adding a filter at the top and/or bottom end of the wrapping medium.

[0053] In some embodiments, the filter can be a paper filter such as a spiral tip paper filter that gives a more even draw than a standard folded or “W’ style filter. Alternatively, the filter can be a wood or glass tips, which can change the look, feel and “smoke” of a joint. Glass tends to stay cool to the touch and gives a sturdy feel to the crutch. Wood also does not transfer heat as much, so it remains cool. Standard, spiral, glass, or wood tips can be put into a cone- or tube-shaped pre-roll.

[0054] The other processing steps (e.g., the steps of method step 180, 180’ or 180”) can be followed by other processing steps, such as weighing the cannabis pre-roll to determine whether the cannabis pre-roll has a pre-determined weight. The cannabis pre-roll can also be inspected to determine an amount of color present at a top portion of the cannabis pre-roll.

[0055] For example, step 180 (or step 180’ or 180”) for incorporating the cannabis particles into a rolling medium (such as a rolling paper, tube or cone, for example a pre-roll tube or cone) can be carried out in various ways to manufacture a cannabis pre-roll with cannabis particles made of < 10 wt.% of particles having a size < 0.425 mm. For instance, incorporating the cannabis material can include packing the cannabis material into the rolling medium with a packing pressure of from about 40 psi to about 120 psi, e.g., about 85 psi. The packing pressure can be obtained with an automated tamper configured for insertion in the rolling medium.

[0056] For example, step 180 (or step 180’ or 180”) for incorporating the cannabis particles into a rolling medium (such as a rolling paper, tube or cone, for example a pre-roll tube or cone) can be carried out in various ways to manufacture a cannabis pre-roll with cannabis particles made of < 15 wt.% of particles having a size of from above 0.425 to 2.0 mm. For instance, incorporating the cannabis material can include packing the cannabis material into a medium with a packing pressure of from about 40 psi to about 120 psi, e.g., about 85 psi. The packing pressure can be obtained with an automated tamper configured for insertion into the rolling medium. [0057] For example, step 180 (or step 180’ or 180”) for incorporating the cannabis particles into a rolling medium (such as a rolling paper, tube or cone, for example a pre-roll tube or cone) can be carried out in various ways to manufacture a cannabis pre-roll with cannabis particles made of least 55 wt.% of particles having a size above 2.0 mm, e.g., at least 75 wt.%. For instance, incorporating the cannabis material can include packing the cannabis material into the rolling medium with a packing pressure of from about 40 psi to about 120 psi, e.g., about 85 psi. The packing pressure can be obtained with an automated tamper configured for insertion into the rolling medium.

EXAMPLES

[0058] The following examples are for illustrative purposes only and are not meant to limit the scope of the compositions and methods described herein.

Example 1

[0059] In this example, cannabis flowers were milled with various size-reduction techniques. The ensuing particles were separated by sieving to measure lots of cannabis particles of different sizes. The resulting particle size distribution (PSD) for each technique is shown in FIGS. 6A-6D. FIG. 6A shows the PSD of cannabis particles for six different strains of cannabis using a shredding technique that employs aggressive impact to break down the cannabis. In particular, a Futurola Mega Shredder machine with an internal 3 mm screen was used. As can be seen from FIG. 6A, the resulting particles included significant fractions (up to approximately 10%) of the 0 mm screen size as well as the 0.25 mm size undesirable fine particles. This indicates that a significant fraction of trichomes were separated from the cannabis flowers by the processing.

[0060] FIG. 6B shows the PSD of three strains of cannabis following milling in a milling machine. In particular, a Mobius M21 Mill™ with a 2.0 mm screen was used. As can be seen from FIG. 6B, the resulting particles had a very inconsistent PSD, with approximately 20-30% of the particles having a 0.25 mm size and up to 10% of the particles being even smaller.

[0061] FIG. 60 shows the PSD of two strains of cannabis following a combination of the prior two techniques, of shredding with a high impact shredder followed by milling in a milling machine. As can be seen from FIG. 60, the resulting particles were highly pulverized, with approximately 22% of the particles having around a 0.25 mm size and 30% of the particles being even smaller. [0062] FIG. 6D shows the PSD of four strains of cannabis following a combination of two techniques as described herein: shredding with a low-impact shredder (the Industrial Monster™ shredder) followed by the prior technique of milling in a milling machine. One of the strains were shredded with a 1.6 mm rasp screen and three with a 2 mm rasp screen. As can be seen from FIG. 6D, the resulting particles in all instances had very few small-sized particles, with the majority of particles being larger than 2 mm. Three of the cannabis strains tested had particularly uniformly large-sized particles, the Grace, NLxBB and Meridian strains, having a PSD with a single mode at the largest sieve size used to grade the particles.

Example 2

[0063] In this example, cannabis flowers milled with the combined low-impact pre-shredding and milling technique as described herein were formed into cannabis pre-rolls using an AutoCone automated rolling system. Three strains were tested, the Grace, NLxBB, and Meridian strains with the low-fine PSD shown in FIG. 6D.

[0064] Pre-rolls were rolled using the Grace strain of cannabis following low-impact shredding and milling with 2 mm rasp screen, with a PSD as shown in FIG. 6D. The auger used in the AutoCone machine demonstrated no signs of fouling and demonstrated low friction and resistance to the product volumetric dispensing. These results were in comparison to the same Grace strain that was milled with a 1/8” rasp screen, as compared to a 2 mm rasp. Results showing the number of successfully rolled pre-rolls vs. unsuccessful ones are shown in Table 1.

[0065] Pre-rolls were rolled using the NLxBB strain of cannabis following low-impact shredding and milling with 2 mm rasp screen, with a PSD as shown in FIG. 6D. All the produced cones were consistent in height and had no signs of bridged product at the filter tip. The cannabis particles bridged in the hopper halfway through the run and required to be tapped loose to stabilize the volumetric dispensing, which is why there was an increase in rejects for this test as shown in Table 1.

[0066] Pre-rolls were rolled using the Meridian strain of cannabis following low-impact shredding and milling with 2 mm rasp screen, with a PSD as shown in FIG. 6D. Cone quality remained positively consistent in height and visual appearance. Meridian AutoCone efficiency was the highest as shown in Table 1.

Table 1

[0067] Reducing the auger pitch width may provide improvement in the efficiency.

Example 3

[0068] In this example, the intent was to identify and note the performance of co-manufactured pre-rolls when subject to a simulated burning test. This test aimed to identify the burning quality of the different elements of combustibility such as fire-holding capacity, the rate, evenness and completeness of the burn.

[0069] Two batches of pre-rolls were provided. In the control group, the pre-rolls were rolled with 0.6 grams of the NLxBB strain of cannabis and in the treatment group the pre-rolls were rolled with 0.5 g of the NLxBB strain of cannabis following low-impact shredding and milling as described above.

[0070] The burn test was performed in a well-ventilated room directly under a fume hood. A peristaltic pump was connected to the pre-roll filter exposing the opposite end to the fume hood. Pre-rolls were clamped in a vertical position allowing for a top to bottom burn. The pre-rolls were lit at the top end and the pump was set to start at 280 rpm. During the burn test, the pump was set on for two seconds on and off for ten seconds to replicate a natural smoking scenario. Random pictures were taken of the lit pre-roll after half of it had been consumed and again once the burn had reached the filter.

[0071] The burn profile was evaluated based on the evenness or ‘uniformity’ of the burn and its capacity to hold the combustion until completeness of the burning zone. Non-uniformity in the packing due to wide particle size distribution impacts the burn profile of the pre-roll. This nonuniformity in the burn profile is observed as a ‘run’ or ‘canoe’. These phenomena are expected and acceptable to a degree. If an appreciable amount of cannabis is left inaccessible to smoke due to a non-uniform burn, the pre-roll is deemed unacceptable. For the purpose of this study, a failure will be defined as more than 15 mm (50% of pre-roll length) of an analyzed pre-roll being left inaccessible or left ‘on-the-table’ post-burn. Burn testing was performed and the results were also noted, and a pass or fail rating was assigned to each unit determined by the length of remaining pre-roll or “run”. The results for 20 units of each batch can be found in the tables below.

11 pass 55%

9 fail 45%.

Table 2 - Burn test measurements and observations for control specimens

15 pass 75%

5 Pail 25%

Table 3 - Burn test measurements and observations for new method pre-rolls

[0072] For control pre-rolls, the burning exercise resulted in a 100% completeness of the burn and all pre-rolls withheld combustion throughout the exercise. All pre-rolls experienced some degree of canoeing at different degrees. Half the samples exhibited minor canoeing at the point of ignition and the majority continued to burn unevenly until the filter section resulting in major canoeing leaving more than 50% of the burning zone asymmetrically consumed. This suggests great variance in pre-roll packing uniformity. This resulted in almost half of the control pre-rolls failing the burn test.

[0073] For treated pre-rolls, the burning exercise resulted in a 100% completeness of the burn and all pre-rolls withheld combustion throughout the exercise. Six samples demonstrated canoeing at point of ignition and only five exhibited uneven burn pattern until the filter section resulting in major canoeing. Accordingly, only five of the twenty tested samples exhibited more than 50% of the burning zone being asymmetrically consumed during the burn test, or a pass rate of 0.75. A passing rate of 60% (or 0.6) or higher (e.g., 65% or higher, 70% or higher) is considered by the present inventors as representing a significant improvement over the untreated pre-rolls.

[0074] Overall, this burn test comparison study demonstrated that the performance of the prerolls with pre-milled cannabis was greatly increased when compared with the untreated counterpart.

[0075] From the untreated control batch, only eleven samples tested successfully passed burn testing while nine samples had a major run or remaining cannabis material larger than 15 mm and were considered a failed unit. This is a passing rate of 55% compared with the pre-milled batch where 15 samples successfully passed for an 75% passing rate.

OTHER EMBODIMENTS

[0076] A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other embodiments are within the scope of the appended claims.

[0077] Other examples of implementations will become apparent to the reader in view of the teachings of the present description and as such, will not be further described here.

[0078] Note that titles or subtitles may be used throughout the present disclosure for convenience of a reader, but in no way these should limit the scope of the invention. Moreover, certain theories may be proposed and disclosed herein; however, in no way they, whether they are right or wrong, should limit the scope of the invention so long as the invention is practiced according to the present disclosure without regard for any particular theory or scheme of action.

[0079] All references cited throughout the specification are hereby incorporated by reference in their entirety for all purposes.

[0080] Reference throughout the specification to “some embodiments”, and so forth, means that a particular element (e.g., feature, structure, and/or characteristic) described in connection with the invention is included in at least one embodiment described herein, and may or may not be present in other embodiments. In addition, it is to be understood that the described inventive features may be combined in any suitable manner in the various embodiments. [0081] It will be understood by those of skill in the art that throughout the present specification, the term “a” used before a term encompasses embodiments containing one or more to what the term refers. It will also be understood by those of skill in the art that throughout the present specification, the term “comprising”, which is synonymous with “including,” “containing,” or “characterized by,” is inclusive or open-ended and does not exclude additional, un-recited elements or method steps.

[0082] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. In the case of conflict, the present document, including definitions will control.

[0083] As used in the present disclosure, the terms “around”, “about” or “approximately” shall generally mean within the error margin generally accepted in the art. Hence, numerical quantities given herein generally include such error margin such that the terms “around”, “about” or “approximately” can be inferred if not expressly stated.

[0084] Although various embodiments of the disclosure have been described and illustrated, it will be apparent to those skilled in the art in light of the present description that numerous modifications and variations can be made. The scope of the invention is defined more particularly in the appended claims.