Tobacco Documents Online

T 0 ~J 7j¸ ° ! ! RESTRICTED RESEARCH, DEVELOPMENT, AND ENGINEERING PRODUCT PORTFOLIO E. F. Litzinger January 19, 1984 J • •+ •

CONTENTS PRODUCT CONCEPTS Page CHECKERBOARD ....................... 1 Mouth Freshener ..................... 2 Small Cigar ....................... 2 Delayed Release Menthol ................. 3 Longer Lasting ................... 4 Aromatic Sidestream .................. 4 Low Sidestream ...................... 5 Cigarette Dimensions ................... 6 Colored/Textured Paper & Tipping ............ 7 Oval ........................... 7 ( FILTERS Grooved Filters ..................... 8 LOw Filtration/High Ventilation ............. 9 Duolite ......................... 9 PEl/Alumina ...................... I0 SPCA ........................... II Program Filter ...................... 12 Diethyl Citrate ..................... 13 Chisso .......................... 14 Water Filter ..... ~ ................ 14 FLAVORS Lime-Menthol ...................... 16 Spice-Menthol ...................... 16 Ambroxide ........................ 17 Amhrettolide ....................... 17 PROCESSES Microbial Nicotine Reduction ............... 17 Microbial Nitrate Reduction ............... 18 Small Strip Cigarette .................. 19 Stratified Cigarette ................... 20 LNB ........................... 20 CTO .......................... 21 SDS ........................... 22 C i

C WRAPPERS Page Cigarette Paper Additives ................ 22 Low Citrate Cigarette Paper ............... 23 Thermoplastic Wrapper .................. 23 TOBACCO ADDITIVES UKELON .......................... 24 PACKAGING Swinger Pack ....................... 25 Rally Pack ........................ 25 Master Slide Pack .................... 25 Open-Top Box ..................... 26 Graphic Designs ..................... 26 Shrink Wrapped Case ................... 26 C MISCELLANEOUS Tobacco Substitutes ................... 27 Carbonized Tobacco ................... 28 ii

J l ( PRODUCT PORTFOLIO CHECKERBOARD PRODUCT CONCEPTS C Cigarette smoke deliveries and taste increase from first puff to last puff. The CHECKERBOARD concept provides a flat puff profile with uniform taste from the beginning to the end of a cigarette. This is accomplished by printing checks (squares) with a rapid burn accelerator in a "checkerboard" pattern with check size increasing from the lighting end to the filter end of the cigarette. In this way, the amount of diluting air increases as the check burns ahead of the char line providing greatest dilution of the high tar last puffs. Development cigarettes were printed with blue, brown, white-on-white, and invisible checks. The latter was selected and the cigarette, HALLMARK, was test marketed in Pittsburgh in 1970. A survey of the test market revealed that, even though HALLMARK delivered more puffs through the checkerboard ventilation mechanism, perceived fast burn rate was the main reason it was not successful. t - I -

• j Mouth Freshener ( Of approximately twenty flavors screened, a minty flavor similar to the commercial mouth freshener "Binaca" was selected. The initial approach was to apply the flavor in microcapsules to cigarette paper toward the filter end providing delayed freshness release of long duration in the smoker's mouth. However, the capsules gave a clearly audible popping sound and this approach was abandoned in favor of placing one large capsule in the filter to be manually ruptured at the discretion of the smoker. Capsules containing the mouth freshener from R. P. Scherer were of high quality (stability and long shelf life) and, though appropriate filter assembly had not yet been developed, a viable product was at hand. The project, however, was terminated because of concern by the Law Department regarding possible \ intervention by the FDA in marketing the product. Small Cigar L When cigarette TV advertising was banned in 1970, R. J. Reynolds launched Winchester, a filter tipped small cigar with the same dimensions and not too dissimilar smoke quality of a cigarette. Soon thereafter, B&W developed a competitive product initially called COUGAR, later changed to ZAGAL. The wrapper consisted of 50% Puerto Rican cigar tobacco along with filler, binder, and plasticizer. The t¢ -2-

J i blend was 70/30 Puerto Rican/0riental tobacco. Despite wrapper shrink affecting appearance, the product was only slightly less preferred (45%) than Winchester in a consumer test. The product was rated significantly milder than Winchester and similar on other attributes. The product, pending solution of the wrapper shrink problem, was given approval for test market. However, after the Treasury Department judged ZAGAL a cigarette and not a cigar product and, after Reynolds, under pressure, removed Winchester from TU, the project was terminated. Delayed Release Menthol C This product was intended to give non-menthol smokers cool, refreshing taste in latter puffs. Microencapsulated menthol was applied to cigarette paper at the last third of the tobacco section. However, =~enthol leakage from the capsules and crackling sound, even when the paper was double wrapped over the capsule portion, caused this approach to be abandoned. Chemical additives to tobacco, capable of releasing menthol on smoking, were examined. Monomenthyl maleate worked but gave an off-taste and questionable pyrolysis products. Tetramenthyl titanate released menthol very efficiently but lacked stability (premature release) in cigarettes even when protected with a wax coating. Philip Morris has also been active in this area. Their purpose, however, has been to avoid menthol loss ~n manufacturing by adding non-volatile menthol derivatives to tobacco for menthol release C -3-

( during smoking. R&D examined one of the patented PM menthol derivatives and found the only drawback was that it imparted a slight waxy taste to smoke. Work on delayed release menthol was discontinued in 1977. Longer Lasting ( With the increasing price of cigarettes, smokers are becoming more frugal as evidenced by the sales decline and increased purchase of generics. One way to compensate smokers is to give them more puffs for their money with a slower burning, longer lasting cigarette. A king size cigarette is currently being developed that gives 14-15 puffs with 20 mg tar. This corresponds to about 25% less tar per puff than full flavor KS and I00 cigarettes currently on the market. The cigarette blend is 50% Sir Walter Raleigh Aromatic, 50% flue cured/0riental tobacco. DuPont respondents reacted very positively to the cigarette's taste, noting its smoothness and lack of irritation. Aromatic Sidestream The "ideal" cigarette would have a sidestream aroma pleasing to the passive smoker but with the distinctive taste of cigarette smoke. For example, the aroma of pipe tobacco smoke is generally regarded as pleasant. However, the taste of pipe tobacco smoke in a cigarette is objectionable to cigarette smokers. The problem is one of diverting a -4-

( ( particular type of aroma to sidestream, separate from the taste of mainstream smoke. Even when vanillin, a principal flavor of pipe tobacco, is applied to cigarette paper, the flavor is carried into ~ainstream with a resultant objectionable reaction by cigarette smokers. A promising candidate that came close to providing a pleasing sidestream without disturbing cigarette taste was developed in 1978. A flavor consisting predominantly of coumarin, maltol, cyclotene, and ethyl vanillin was applied to the tobacco in cigarettes tested at DuPont. On single cigarette smoking, the panelists reactions were very favorable; they were impressed by both the sidestream aroma and cigarette taste. However, the cigarette did not wear well. In pack testing~ panelists replied that passive smokers, particularly their children, commented very favorably on the aroma. However, after one or two packs, the panelists found the taste objectionable. Satisfying the criteria of pleasant aroma without disturbing taste is a real tightrope. Reducing and perhaps modifying the flavor of the '78 cigarette remains promising. Low Sidestream t Visible sidestream smoke is due to aerosol particles emanating from near the cigarette burn line. Although it has little or no effect on odor and irritation (invisible vapor phase is the major source of "these sensations), visible sidestream can be a source of annoyance to passive smokers and cause for legislating non-smoking in public Ll C -5-

( buildings, smoker segregation in restaurants, etc. RD&E has evaluated low sidestream cigarette papers from two suppliers, Ecusta and Schweitzer. The Schweitzer paper - high citrate, low permeability - does not reduce sidestream as effectively as the Ecusta paper and causes unsightly tar staining behind the char line. The active ingredient in Ecusta's "VELVET" paper is hydrated magnesium oxide. Tar staining is far less perceptible; however, VELVET causes an off-taste, most often described as chalky and dry. Changes in blend, flavor additives, and paper perforation show promise in overcoming off-taste. ( Cigarette Dimensions Manufacturing is capable of a wide range of cigarette dimensions: cigarettes from 70 to 120 mm length, 21 to 25 mm circumference, and 18 to 27 mm filters. Ordering and fitting parts to existing equipment are the only constraints. B&W has made cigarettes at the extremes in dimensions, from the 70 mm SEVENTY cigarette to the 120 n~u PHOENIX and SUEDES, both 21 mm circumference in dark brown cigarette paper. The latter two were nationally marketed in 1975. FLAIR, a female oriented cigarette in an extremely attractive pack, was marketed in 1970 following the introduction of Virginia Slin~. FLAIR, same length and circumference as Virginia Slims, was discontinued within two years. Twelve years have passed and B&W remains without a female oriented cigarette. With the experience gained in PHOENIX and SUEDES, B&W has the capability of outslimming Virginia Slims. -6-

( L Colored/Textured Paper and Tipping Development Center recently made cigarettes with color coordinated cigarette paper and tipping. Colors ranged from pink and blue to a more subdued cream and beige with axial and circumferential watermarks. Colored cigarettes would seem to have great potential for the female market with color selection limited only by the creative imagination of Marketing. Texturized tipping and paper could also have great appeal. The tipping for Lorillard's Satin cigarette is supplied by Ecusta. Southampton has also developed technology for embossing tipping on finished cigarettes. Schweitzer has made small quantities of embossed cigarette paper. Oval Four U.S. tobacco companies (two major ones) sell or have sold oval cigarettes. The best known is English Ovals manufactured by Philip Morris. BAT Hamburg has developed the technology for manufacturing oval cigarettes. Molins, an equipment manufacturer has a patent application for a garniture system for making oval cigarettes. Ovals can be made to any length, filter or unfiltered. It seems almost bogus for an American company to make English Ovals. As a subsidiary of an English tobacco company, an oval cigarette manufactured by B&W would have a more authentic ring. Imagery could be conveyed in prestige packaging and advertising. The cigarette might be called British Ovals or, perhaps better yet, BATUS Ovals. -7- 7¢

FILTERS Grooved Filters ( L The ACTRON filter is the most revolutionary development in the industry since the introduction of filtered cigarettes. Grooves on the periphery of impermeable plug wrap prevent smoke and ventilating air from mixing until it reaches the smoker's mouth. The velocity differential between the smoke and diluting air causes the smoke to billow in the smoker's mouth contacting more taste receptors than conventionally ventilated cigarettes. This phenomenon, known as spatial summation, causes more taste than is enjoyed in a conventional ultra low tar product. Our adversaries claimed the unusually rich taste is due to smokers draping their lips over the grooves, reducing ventilation and increasing tar intake. Unfortunately, the FTC and federal courts bought onto this contrived allegation and banned i mg tar advertising. Forced into this position, RD&E has developed ACTRON contingencies around the alleged lip drape. Among these contingencies, hole in groove, porous and perforated plug wraps allow diluting air to mix with the smoke and maintain ventilation on forced occlusion of the grooves. In another contingency, the "hot cross bun", the filter end of the cigarette is embossed to recess the grooves to prevent alleged occlusion. t¢ C -8-

( Low Filtration/High Ventilation ( The strategy behind this type filter is to carry further the easy draw and taste success of the ACTRON filter. The purpose of a filter with low filtration and high ventilation is threefold: (I) deliver the full taste of an unfiltered cigarette at low tar, (2) provide easy draw through low pressure drop, and (3) reduce gas phase to a much greater extent than tar. Several approaches were advanced, the first of which was ARIES. ARIES is an injection molded plastic filter with recessed peripheral grooves. Diluting air and unfiltered smoke mix in the smoker's mouth. Other options to ARIES involve grooved dual filters with extruded plastic mouthpieces. One design has the plastic piece at the mouthend with either tobacco or cellulose acetate in the filter adjacent the tobacco column. Another design places the plastic piece near the tobacco column with low efficiency acetate at the mouthend. A final dual design utilizes a grooved extruded plastic piece filled with a closed cell foam. Puolite t A porous granular resin with chemically active groups, Duolite reacts with hydrogen cyanide and aldehydes removing them from smoke. The resin, partially combined with acetic acid to catalyze the removal of aldehydes, was made to B&W specifications by Diamond Shamrock. Removal of irritating aldehydes, such as formaldehyde and acrolein, is -9-

C C %. a key to smoke mildness in Duolite filtered cigarettes. Unlike charcoal, which is indiscriminate in that it also removes flavor compounds, Duolite filters smoke selectively. Also, unlike charcoal, Duolite is compatible with menthol cigarettes. In consumer testing, Duolite gave unprecedented results with 61-39, 60-40, and 57-43 preferences in VICEROY 100, VICEROY Milds KS, and Winston I00, respectively, against the counterpart cigarettes without Duolite. After over two years of extensive testing, FACT, the "low gas" cigarette with a "Purite" filter was launched nationally in early 1974. The cigarette, whether because of its sterile pack or consumers not understanding "low gas", was a failure and was withdrawn from the market. FACT was relaunched in 1976 in an attractive new pack and advertizing stressing taste. However, after failing to achieve its targeted share, FACT was again removed from the market. PEl/Alumina t This filter material, PEI coated alumina, functions the same as Duolite. Alumina granules provide porosity while PEI (polyethylenimine) provides chemical reactivity. Like Duolite, PEl/alumina is combined with acetic acid to enhance aldehyde filtration and improve smoke taste. The amount of PEl/alumina required to give equivalent filtration is 2.5 times that of Duolite. Bowever, PEl/alumina is far less expensive than Duolite and, even though a greater amount is required to match Duolite's performance, - I0 -

( PEl/alumina still nets out at a lower cost. PEl/alumina performed almost as well as Duolite in consumer tests. For these reasons and because of Diamond Shamrock's limited capacity to make Duolite GPA-327, PEl/alumina was being considered for use in FACT, had the cigarette exceeded 1% market share. Addition of zinc acetate to PEl/alumina broadens its filtration to include hydrogen sulfide without affecting hydrogen cyanide and aldehyde filtration or consumer preference. SPCA ( L Shredded porous cellulose acetate is a high efficiency tar removal filter material. It has filtration-pressure drop performance superior to that of conventional cellulose acetate and performance similar to % paper filters at only one-third the weight. SPCA is made by dissolving cellulose acetate in acetone and plasticizer in which starch and saline solution are present. The mixture is heated to swell the starch, rolled into a thin sheet, dried and shredded. The shredded material is washed to remove the salt and enzymatically treated to remove the starch and form the porous structure. Porosity, surface area, and filtration efficiency are dependent on the starch/acetate ratio. SPCA is best used in a dual filter with conventional cellulose acetate at the mouthend to prevent the shredded material from getting into smokers' mouths. B&W negotiated with Celanese to make SPCA but, because of high manufacturing cost, the project was abandoned. - II -

C ( Program Filter The purpose of the program filter is the same as that of the CHECKERBOARD concept, to give constant smoke delivery and taste from first puff to last. The program filter resembles a conventional filter except that it has a plastic tube placed in the periphery of the cellulose acetate. The tube extends about 80% of the length of the filter beginning with the open end adjacent the tobacco section and terminating with the tube closed except for a small orifice. The tube serves as a bypass around the main body of the filter in the early low tar puffs and smoke filtration is low. As smoking is continued, impaction gradually blocks the orifice forcing some of the smoke to pass through the entire length of the main body filter causing the smoke to be more efficiently removed. In the last, high tar puffs, the orifice is ultimately blocked forcing all of the smoke to pass through the main body of the filter. The overall effect of the tube is to cause progressively increasing filtration as smoke concentration increases, netting out to a constant delivery per puff. Machinery development to manufacture cigarettes with the program filter had just begun when other priorities forced its discontinuation. L - 12- A: %¢

Diethyl Citrate In 1972, New York City passed a law placing an additional tax on cigarettes exceeding 17 mg tar and i.I mg nicotine. B&W products were within the tar limit but over the limit on nicotine. A search was initiated for an easily implemented filter additive to selectively reduce nicotine delivery. Organic acids and polyols reduced nicotine but were incompatible with filter plasticizer. Diethyl citrate, an organic acid ester, however, was compatible with plasticizer and quite effective in reducing nicotine deliveries. Results of tests with DEC in UICEROY KS and KOOL KS lowered nicotine delivery 0.2 mg without affecting consumer acceptability and was given product approval. After a brief time, the New York tax law was rescinded and DEC was not implemented. In 1982, government imposed constraints in the Saudi and Gulf markets necessitated reductions in nicotine deliveries of B&W international brands. Negotiations for licensing rights were initiated with Reemtsma, the owner of the U.S. patent rights to DEC. However, Reemtsma's royalty fee was inordinately high and filter ventilation was implemented or increased to reduce nicotine deliveries from these products. The Reemtsma patent on diethyl citrate expires in January, 1986. - 13-

( Chisso This filter is made by Chisso Corporation of Japan. The individual fibers are composed of a polypropylene core with a surface of ethylene vinyl acetate-polyethylene copolymer (EVAIPE). The fibers can be manufactured with the polypropylene completely enveloped by EVA/PE or with 10-15Z of the polypropylene exposed to the fiber surface. Compared to cellulose acetate, initially submitted Chisso filters gave a smoother, more flavorful smoke at lower tar (I0 vs. 13.5 mg). A problem with the first Chisso filters was high pressure drop. Subsequent filters with reduced pressure drop showed diminution of the positive effects of Chisso. Nevertheless, its multicomponent composition offers potential for manipulating smoke quality - polyethylene and polypropylene for nonpolar compounds in smoke, vinyl acetate for polar compounds. Future work will examine moderate to low pressure drop Chisso filters with 85-90% to complete EVA surface exposure. Low to high vinyl acetate content EVA will also be examined. Chisso is somewhat more expensive than cellulose acetate, however, the cost is offset in that Chisso requires no plug wrap. Water Filter ~ater is a very effective medium for cigarette smoke. It removes hydrogen cyanide and vapor phase compounds such as formaldehyde and acrolein, enhances the selectivity of filter additives, and effects a marked reduction in smoke irritation. Water does not have the same Lq - 14 -

( adverse effect on taste as charcoal; it reduces flavor amplitude but does not affect flavor character. Southampton developed a pilot process for encapsulating water in cylindrical capsules in 1968. However, because of problems in speed of capsule manufacture and filter assembly, 3M was contracted to make spherical water containing wax capsules. B&W was given responsibility for working with 3M and evaluating capsule stability and effects on smoke quality. (The single large capsule in the filter was ruptured manually by the smoker.) By the end of 1970, 3M had developed water capsules of high quality and B&W evaluations showed, except for a reduction in flavor amplitude, favorable effects on smoke, particularly reduction in smoke irritation. However, with other activities, such as CHECKERBOARD taking precedence, work was discontinued. Since then we have seen the inception and tremendous growth of ventilated low tar cigarettes. Filter ventilation brought with it, however, problems of weak taste and mouth dryness. Water capsules could well be a solution to these problems. Dry mouth relief is an obvious potential application. However, in addition, water soluble flavor and salivating additives, could be incorporated in the capsules to improve the sensory quality of ventilated low tar cigarettes. - 15 - C

FLAVORS Lime-Menthol C In quest of a highly recognizable, uniquely flavored cigarette, a lime-menthol product was developed and consumer tested in 1970. Lime oil was added in filter manufacture, menthol to tobacco in the conventional manner. Consumer reaction was polarized; very few smokers had a neutral opinion. Overall, more smokers liked the idea of a lime-menthol cigarette than disliked it. Image data indicated the product as strongly female oriented, young, active, and stylish. Encouraged by the consumer test results, the cigarette, LYME, was placed in Test Market in Fort Wayne, Indiana in October, 1971 and Tampa - St. Petersburg in February, 1972. While the Fort Wayne market was more favorable, overall, results indicated LYME an occasional cigarette to smokers and the product was withdrawn from test market. Spice-Menthol t With early indications of success with LYME, a project was initiated in February, 1972 to develop other uniquely flavored cigarettes. Results with bourbon, wine, cherry-menthol, and uncola-menthol flavored cigarettes were encouraging but spice-menthol showed the most promise and was consumer tested. Spice-menthol cigarettes were made with cinnamon flavor applied in filter manufacture, menthol on,the tobacco. Consumer acceptance and image were similar to LYME and, like LYME, spice-menthol was perceived as an occasional cigarette and was not pursued further. - 16 - C

Ambroxide This flavor compound (a napthofuran) was isolated by R&D as a pyrolysis product of Amarelinho (Brazilian flue-cured) tobacco. Ambroxide is extremely potent, imparting a heavy, air cured, cedar-, and cigar-like character to smoke. Cigarettes with ambroxide possess more tobacco taste than might be expected from their tar deliveries. Ambroxide is currently used in BARCLAY and KOOL Ultra products. Ambrettolide ( Isolated by R&D from the smoke of Wisconsin Cigar Leaf (a fermented tobacco), this musk flavor compound imparts a unique nutty and smooth character to cigarette smoke. Ambrettolide is currently used in BELAIR KS and RICHLAND Menthol. PROCESSES Microbial Nicotine Reduction t In this process, tobacco is subjected to the action of a microorganism which selectively degrades nicotine biochemically. The microorganism, a common one found in soils, is used to innoculate a nicotine broth containing small amounts of yeast and minerals. The source of nicotine may be burley stem or may come from partial extraction of the tobacco to be treated. The innoculum is diluted with a weak solution - 17- C

( of ammonium hydroxide to a volume sufficient to spray onto tobacco to achieve at least 60% moisture. After spraying, the tobacco is bulked for a prolonged period before drying (the microorganism is destroyed during drying). The nicotine content of 50 pounds of burley tobacco processed for consumer testing was reduced 50% after six hours bulking. Consumer test results showed a preference standoff between VICEROY KS (1.3 mg nicotine delivery) and VICEROY KS with microbially treated burley (i.0 mg nicotine). Microbial Nitrate Reduction ( L This process is similar to the one previously described for nicotine. Two microorganisms can be used, one that is specific for nitrate only and one that is both nicotine and nitrate specific. Since current interest is in cigarettes with low nitrogen oxides deliveries, the nitrate specific microorganism has received greater attention. The process is applicable to burley lamina and, more particularly, to burley stem extract in reconstituted tobacco production. Pilot scale denitrification of PJS extract add-back was carried out in 1981 in collaboration with the Schweitzer Division of Kimberly-Clark. The B&W process produced an 88% nitrate reduction in reconstituted sheet, 0.40% nitrate compared to 3.23% for normally processed sheet. Other chemical changes were a small nicotine loss, from 0.98X to 0.84%, and almost complete loss of sugar. Consumer product test results showed no differences in KOOL KS with the low nitrate PJS and KOOL KS with - 18 -

C normally processed PJS. PJS content in both cigarettes was 13%. The low nitrate KOOL KS delivered 23% less nitric oxide. Estimated cost for incorporation of the B&W process into PJS production is I-2~/I000 cigarettes. Small Strip Cigarette ( The physical appearance of small strip is quite different from cut tobacco. It is small uncut lamina, a mixture of randomly shaped particles approximately one-quarter inch in size, generated from whole leaf threshing. Small strip was pursued initially for its high fill value. However, cigarettes were made entirely from small strip with the idea of using its unique appearance to a marketing advantage. The small strip cigarette delivered more flavor with less tar and nicotine % per puff than either VICEROY KS or an all lamina cigarette made from cut tobacco. The availability of "natural" small strip, however, was only enough to support 1 1/2 share points of a new brand. A small strip generating process was developed in 1977 using a hammermill capable of size reduction without excessive fines generation. Add-on cost for the small strip cigarette has been estimated at 34~fi000 over a conventionally blended cigarette. Inclusion of 20% shattered PJS reduces the add-on cost to I04/i000 cigarettes. L - 19 - Cl

Stratified Cigarette It has been a long standing belief that sidestream smoke comes from tobacco in the core of a cigarette while mainstream is generated from tobacco on the periphery. Philip Morris has a publication that supports this view. Advantage can be taken of this phenomenon by placing flavorful lamina at the periphery and, stem and reconstituted tobacco in the core of a stratified (annular) cigarette. RD&E has modified a Garant 4 maker and produced VICEROY KS cigarettes with PJS and WTS in the core with lamina at the periphery. An internal smoke panel perceived less irritation from the core stratified VICEROY than a conventional VICEROY of the same blend composition. With this indication that stratification affects smoke sensory properties, a future verification test has been planned comparing cigarettes with the core and periphery tobaccos interchanged. Improvements have been made to the maker to give better core stratification and more readily detectable differences in smoke character. LNB t Burley stem is very high in nitrate (ca. 7%) and is the main contributor to the nitrate content of B&W blends. Reducing nitrate is important in lowering nitrogen oxides delivery in smoke. WTS, which is comprised of roughly 50% burley stem, 50% flue-cured stem, is present at 17% in some B&W blends. Since hurley stem contains very little nicotine or flavorful compounds, simple water extraction is the - 20 - .j

( ( most expedient route to low nitrate burley (LNB) stem. Water extraction removes 90% of the nitrate from burley stem with a 30% mass loss. This lost mass contributes nothing to fill value and, therefore, no additional burley stem is added to compensate. Consumer test results conducted in 1978 showed a preference standoff for VICEROY KS with extracted versus unextracted burley stem. Blend nitrate was 35% lower as a result of burley stem extraction and nitrogen oxides delivery was reduced 20%. Removing nitrate from WTS does not reduce the burn rate of this fastest burning blend component, presumably because extraction makes it more porous exposing more surface area for combustion. Nitrate removal is important, however, in that nitrate counteracts and renders ineffective reasonable amounts of burn retardant added to WTS to slow its burn rate. CTO Cut tobacco overdrying (CTO) is a process by which tobacco at 21% moisture is cut, overdried to 6%, and reordered to 14% moisture for cigarette manufacture. WTS and expanded tobacco are added to the blend after reordering and prior to flavoring. In general, CTO seems to have a positive effect on non-menthol cigarettes giving a smoother, less irritating smoke. The effect, however, may be blend specific and work is currently on-going. - 21 - C

SD__SS Shredded dried stem (SDS) is a new stem expansion process much _superior to WTS. In contrast to WTS, SDS has somewhat the appearance of finely cut lamina. When implemented, SDS should go a long way in reducing consumer complaints about chunks of stem in cigarettes and, about holes in cigarette paper caused by stem. At equal firmness and puff number, SDS provides 4% density reduction, 20% lower tobacco section pressure drop, and i0% less carbon monoxide at equal tar compared to WTS, both at 17% level in the blend. ( Cigarette Paper Additives WRAPPERS Additives to cigarette paper are important to ash appearance, burn rate, and smoke taste and deliveries. Most domestic cigarettes use sodium/potassium citrate (a burn accelerator) as a paper additive, very few use monoammonium phosphate (a burn retardant) because of high carbon monoxide. In 1975, R&D evaluated 25 cigarette paper additives. Only a few showed any merit over currently used citrate paper. Sodium/potassium succinate gave better ash appearance with slightly fuller taste. Ammonium pentaborate reduced cigarette burn rate without increasing carbon monoxide. Smoke quality was similar to citrate and ash appearance somewhat worse. Magnesium carbonate reduced both burn rate and carbon monoxide, and reduced smoke irritation, but gave a very flaky ash similar to chemical free paper. - 22 - C~

( Low Citrate Cigarette Paper ( Chemical free paper gives low carbon monoxide but cigarettes with this paper have poor ash appearance. Phosphate and citrate improve ash appearance but, while both increase CO over chemical free paper, the increase is much greater with phosphate. Paper permeability also affects CO delivery, as well as smoke taste. High permeability papers are particularly undesirable since they magnify first puff to last puff differences in taste strength as the paper is consumed during smoking. Work began in 1977 examining the effects of citrate and paper permeability on CO deliveries. It was found that citrate was the more dominant factor and that CO decreased dramatically below 0.5% citrate. In 1979, 40 CORESTA/0.3% citrate paper was used for the first time on a B&W brand. Today this paper, Schweitzer 544 and Ecusta 14211, is used on 80% of our domestic cigarettes. Thermoplastic Wrapper t This cigarette paper evolved from the observation that the wrapper on the small cigar, ZAGAL, caused a selective reduction in nicotine delivery. Rapaport, maker of the small cigar wrapper, was contacted to make a similar white wrapper for cigarettes. The nearly white wrapper consisted mainly of 28% each titanium dioxide, finely ground hurley stem, and cellulose acetate and methyl cellulose, thermoplastic materials in a 4:1 ratio. The wrapper reduced VICEROY KS nicotine delivery by 30% while reducing tar only 10%. An increase in tobacco - 23 - C -J C

section water content during smoking caused a pressure drop increase from &.8 inches on the first puff to 6.6 inches on the last. While the thermoplastic wrapper reduced VICEROY KS harshness, it imparted a less pleasant taste to smoke. The off-taste was attributed to the burley stem and was subsequently replaced with finely ground paper. A small amount of potassium nitrate was added to enhance selective nicotine reduction. TOBACCO ADDITIVES ( UKELON The additive decomposes to ammonia on pyrolysis increasing smoke pH and impact. UKELON (urea) reduces cigarette aldehyde deliveries but slightly increases hydrogen cyanide. It is unacceptable as an additive to blended cigarettes in that it imparts too much burley character to smoke. However, UKELON added to an all flue-cured cigarette provides a taste very similar to that of a blended cigarette. An added benefit of an all flue-cured, UKELON treated cigarette is very low delivery of nitrogen oxides due to the absence of burley tobacco. Combining a Duolite filter with a @lue-cured/UKELON tobacco section gives a cigarette with greatly reduced gas phase - nitrogen oxides, aldehydes (i.e., acrolein), and hydrogen cyanide. In addition to its effects on smoke chemistry and smoke character, UKELON, as a burn retardant, increases cigarette puff number. - 24 - -j

Swinger Pack PACKAGING This pack (A) consists of an outer shell with an inner shell mounted inside for swinging movement relative to the outer shell. The inner shell is movable from a position completely enclosed within the outer shell to an angular position for removing cigarettes. In a 1980 consumer product test, the swinger pack received a significantly higher rating than the conventional soft pack, even though there was some difficulty with opening. ( Rally Pack This pack (B) has scored side panels so that the pack folds and collapses as cigarettes are removed. The rally pack offers the protection of a hard pack without the continued discomfort encountered when carried in a person's pocket. Rally Pack was tested at DuPont in 1978 and received a high degree of rejection based on appearance. Master Slide Pack This pack {C) was used in HALLMARK, a prestige cigarette, test marketed in Nashville in 1976. The product, due either to an unsophisticated market or difficulty in opening the pack, was unsuccessful. C - 25 -

( f ' -O Ill ,N' J u A • / i~1 ~,Y .PV, /"J" B C Open-Top Box ( This hard pack is identical in appearance to a soft pack. It is not a flip-open box and is opened in the same manner as a soft pack. The open-top box also tested well against a conventional soft pack in the 1980 CPT. % Graphic Designs B&W has the know-how to improve pack and carton appearance through foamed texturizing inks, hot foil die stamping, and embossing techniques. Shrink Wrapped Case t B&W was the first company in the industry to wrap cigarette cases in moisture barrier polyethylene film. This type protection, first used in the BARCLAY launch, dramatically reduces moisture loss in shipment and warehouse storage. C .J - 26 -

( Tobacco Substitutes MISCELLANEOUS ( t These materials, basically inert fillers, act as diluents in reducing cigarette smoke deliveries. Two notable tobacco substitutes - Cytrel, a product of Celanese, and NSM, developed by ICI and Imperial Tobacco - were evaluated by B&W. Both caused severe manufacturing problems. Low physical strength and, particularly, high water sensitivity caused the materials to disintegrate during primary processing. R&D initiated a project in 1973 to develop a water resistant tobacco substitute of high physical strength. Two substitutes were developed, both band cast containing 50% alumina trihydrate as inert filler. One substitute was solvent cast from a methylene chloride/methanol slurry containing % methyl cellulose binder and cellulose acetate to impart water resistance. The second substitute was cast from a water slurry containing sodium carboxymethylcellulose binder and glyoxal to crosslink the binder during band drying to give water resistance. Ash problems, encountered with tobacco substitutes, were overcome by incorporating (a) 5% borax to fuse the ash and prevent flaking and (b) 15% manufacturing fines and 5% sodium citrate to prevent ash blooming. In addition, both the water cast and solvent cast tobacco substitutes contained ca. 3% paper fiber for added strength. Consumer tests of each of the two substitutes at 20% inclusion in VICEROY KS showed no distinguishable difference from normal VICEROY KS controls. In contrast to a half puff reduction with Cytrel and NSM at this inclusion level, the B&W tobacco substitutes gave a full puff increase. C - 27 -

A Ib ( ( Carbonized Tobacco B&W generates annually millions of pounds of very small tobacco particles in WTS production. While some of this material, WTS meal, is used in the manufacture of reconstituted tobacco, large quantities are discarded. Work was carried out in 1975 to utilize this waste by carbonization and conversion into a sheet material with low smoke delivery. Temperatures of 550-650°F completely charred the WTS meal yielding ~0-45% carbonized material. The powdered WTS char was converted into a water resistant sheet using glyoxal crosslinked sodium carboxymethylcellulose binder. The shredded sheet, incorporated into VICEROY KS at 25% inclusion, gave reductions in tar and nicotine of 20-25%, and 50% in hydrogen cyanide. While some problems may have been anticipated with tobacco substitutes containing non-tobacco material (i.e., Cytrel, NSM, B&W's alumina based substitute), there was less likelihood of this occurring with the WTS char sheet since, except for binder, the material was tobacco derived. 2198M L - 28 -

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BROWN & WILLIAMSON - LOUISVILLE DOCUMENT CONTROL PROJECT THREE-RING BINDER VARIANCE SHEET ( ) DOCUMENTS IN FRONT INSIDE POCKET. ( ) DOCUMENTS IN REAR INSIDE POCKET. ( ) DOCUMENTS LOOSE IN FRONT OF BINDER. DOCUMENTS LOOSE IN REAR OF BINDER.

o PRODUCT RESEARCH AND DEVELOPMENT REVIEW: "e 3ANUAEY 19n 1984 B:00 - 8:15 8:15 - 8:45 8:45 - 9:30 Break 9:45 - 10:15 10:15 - 10:45 10:45 - 11:15 11:15 - 12:00 Lunch I:00 - 2:00 2:00 - 2:45 Break 3:00 - 3:30 3:30 - 4:00 4:00 - 4:30 4:30 - 5:00 5:00 - 6:30 Introduction Leaf and Blend Research & Development Domestic Noumenthol Products Domestic Menthol Products Export Products Material Utilization Process Evaluation for Product Improvement Product Research General Discussion of B&W Product Strategy Licensee Services Packaging Research & Development Sensory and Behavioral Research Closing Discussion Cocktails MLR PRF AM DVC BBC JWE DLS ~GB TFR to head PLA KAF WHD to head Other product attendees, JGE, DLC, RTL, TFR, HCW, EFL, and DMF. Purpose is for communication to other RD&E departments to develop coherent and mutually supportive technical programs. Not a show and tell session so don't spend too much time on preparation, art work, etc. We will use acetates. 0823n -d