Low-density tobacco filler and a method of making low-density tobacco filler and smoking articles therefrom

A low-density filler material for cigarettes from either a low-density tobacco composition or an extruded grain or starch composition. The low-density tobacco composition and a method of making the low-density tobacco composition by extruding a mixture of tobacco and flour or tobacco and starch under conditions whereby the solvent in the extruded mixture flashes into vapor upon release from the extrusion head. The low-density tobacco composition is formed without the aid of an added binder. The low-density flour or starch material and a method of making it by extruding flour or starch with a filler material such as calcium carbonate under conditions whereby the solvent in the extruded mixture flashes into vapor upon extrusion through the orifice die. The extruded composition can then be cut and used in place of cut tobacco filler.