Product Design
Monthly Development Summary - May, 1990
Abstract
Catalogues the status of 32 Philip Morris Cos., Inc. [PM] and Philip Morris Cos. International, Inc. [PMI] product development projects. Reports experimental low sidestream [SS] cigarettes demonstrate a 50 plus percent reduction in smoke visibility, Marlboro modifications provide favorable subjectives and concentric filter design findings are being summarized. Lists international projects underway, compiles results of competitive testing and summarizes the current status of PM cigarette design.
Fields
- Author
- Houghton, Kenneth S., Ph.D. (Senior VP of R&D at Philip Morris)Defense
- Recipient
- Serrano, Mark A. (Senior VP of Operations, PM)Senior VP of Operations. Formerly head of Park 500 (RL factory where Uydess worked on de-nitration process improvement.) Sent to South Africa to buy tobacco among other purposes
Changes in cigarette design over the past half century.
Design changes to achieve altered FTC smoke machine tar and nicotine ratings, with or without measured changes in human intake.
Are cigarettes designed to cater to individual inhalation profiles?
Research and development of novel nicotine delivery devices and experimental tobacco designs.
Modification of low yield products to assure that adequate levels of nicotine delivery are maintained, and effects of yield changes on toxicity and dependence.
Modification of selected mainstream smoke constituents in response to health concerns.
Measuring the effects of changes in human smoking behavior on intake of nicotine and smoke constituents.
Design changes which alter nicotine delivery or effect how the product causes and maintains dependence, including transfer of nicotine from tobacco to smoke, and uptake into the body.
Design changes to reduce perception of environmental tobacco smoke among smokers and nonsmokers in response to public concerns about the dangers of ETS.
Modification of selected sidestream smoke constituents in response to health concerns.
Development of methods for measurement of gas and particulate yields in mainstream and sidestream smoke.
Modification of tobacco products through use of additives and measuring effects on dependence, behavior, and toxicity.
Modification of tobacco products through use of filters, paper, and ventilation, and measuring effects on dependence, behavior, and toxicity.
Modification of tobacco products through changes in tobacco processing and use of blends, and measuring effects on dependence, behavior, and toxicity.
Puff parameters, daily intake, etc.
PM @expanded_tobacco especially during 1980's and early 1990's
Early PM @reconstituted_tobacco
PM @reconstituted_tobacco, c. 1970s-1980s
Philip Morris project c. 1992-96
AFIL has a "bonded fibers segment" and a "plastic products segment" and is apparently involved in the tobacco industry
sold materials for cigarette filters
Fabriques de Tabac Reunies, Philip Morris Research and Development facility in Nuechatel, Switzerland. Many of the documents generated by this facility are in German or French language.
Specializes in the tobacco reconstitution process and in helping the tobacco companies control their nicotine
CEO George Benda has traveled the country pushing ventilation as a solution to the problem of secondhand smoke.
Document Images
PI3III.IP MORRIS U. S. A.
C
INTER-OFFIC'E COR'RESPONDE'NCE
Richmond, Virginia
To: Dr. M. A. Serrano Date: June 114, 11990
From:
Subject: K. S. Houghton
1V7onthlv,Deyelnpment Summary - Mav:1994'
C90'03305
11. Project ART:
- product: Three adalimionaf monadic ART tests (0704, 0705, 0706) were completed
and the results were analyzed along, with the previous monadics. The results for the
controli ART and the 4 distinctive flavors generally showed that the control ART
without casing and aftercut was rated more favorably than the other cigarettes by the
ultra lbw smokers. T'he flavor low smokers did not find any significant differences
between cigarettes on acceptability and strength. There were delivery effects on all
three scales (acceptability, strength, and purchase intent). That is,, the ultra low
smokers rated the 6 cigarettes higher than did the flavor low smokers. There was a
cigarette effect on the purchase intent question. This showed that the cigarettes
tested in POL 0705 were! significantly different~ than~ all the other cigarettes. Note:
the cigarettes tested in POL's 0705 and 0706 were the -same cigarettes; however, the
smokers ini POL 0705 prior to receiving their cigarettes were mailed a concept card
that asked them to evaluate the ART concept. The results showed that ratings on the
'intent to buy' question were higher prior to smoking,the ART cigarettes than after.
Production of the &4zH De-Nic Ad'i Pack test will be schedulled tentatively for June
when packaging materials are available. Cigarette specifications for the B&H De-
Nic tests have been modified for an 83 mm FTB' and a 100 mmi F'TB, menthol and
non-menthol. A factory trial~ prior to Ad Pack production, is being requested.
Prototypes were produced using the current 215 blend with charcoal-on-tow dual
filters. Charcoal loadings were 30 mg,, 45 mg and 60 mg; Siubjective testing is in
progress. A POL test is planned to evaluate an ART prototype with a charcoat filter.
POL 3637 (Marlboro control versus Marlboro with 2% MPC ART stems in RCB) was
shipped and will close out the week of June 7, 1990! Since 2% dbuble-batched citric
acid stems in Pilot Rl, and 5% in RCB were subjectively comparable to their
respective single-batchi tests, combinations of RL and RCB with double-batched
stems in Marlboro have been requested.
- Ha1f-Nic Brand Extensiion: The target brand" family for this program has been
changed from B&H to Merit. Work involving, the B&H samples is being completedl
Adjustments have been made to the previously develbped B&H-type total blend
casing to bring it more in line with Merit. A new total blend casing, -91iA, was also
developed and~ is being applied to blend' 232. Two new aftercuts and the current
Merit aftercut are being evaluated on blend 232 with~ both of the total blend casings
described~ above. An alternate approach, to this program is also being pursued. The
current ART blend, 215, is being, used' as a base with Merit filder being added back.
This new blend is 55% extracted blend 215 (215-DLF3B) and 45% Merit blend
components. Models wi th this new blend will be available the week of'Jnne 4', 1990.
A tar/nicotine interaction study to assess 100 mm models from, 3 to 15 mg tar and from
0:3' to 1.5% filler nicotine is in progress: Prototypes have been made, analyzed and
are currently being subjeetively evaluated~ by the PED panels. This study is expected
to be completed in early June.
- Li guid Absorber Process: The commercial simulation trial of the countercurrent
staging concept was completed with a total of 11 back-to+back extraction runs.
Three stages with 20 gallons each of 6% CA/MPC solutnoni (starting pH=3) were
used for each run. As expected, the nicotine levels on each stage increased
somewhat', as the process lined out but had' no adverse effect on absorption efficiency.
The tobacco from these runs has been made into cigarettes by Flavor Development
and is currently being smoked to determine the subjective impact of this mode of
operation.
The pilot plant completed' a series of tuns designed~ to investigate the causes of batch-
to-batch variations in extracted filQer nicotine levels. A more extensive method! was
implemented for profiling the extracted filler bed for nicotine. The results show that
the final nicotine level varied from about 0.06% at the bottom of the filler bed to
about 0.15% at the top for standard liquid absorber process conditions (200 M/M)i
This variability within the tobacco bed has been responsible for mu& of the apparent
batch-to-batch variation. This variation, wi th2n, the extracted filler bedl occurs with
stem as the absorbent as well, so it is striietly an extraction, rather than absorption,
phenomena. Increasing the extraction time to 250 M/M reduces the variation to
0,06% - 0.09% throughout the filler bed. Additional extraction tests are currently in
progress to fully characterize the nicotine distribution as a function of M/M.
- Liquid Absorber Effluent Dis p~al: A series of lab studies has just been completed
by Biochemical' Research in which the bioconversion of nicotine was successfully
demonstrated using an input stream that would' result from combining water column
effluent with Park 500 effluent to the waste treatment plant. These data were
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favorably received: by Park 5W management. A request was made to run another
series of lab trials simulating a pretreatment of effluent from the water column albne
which means treatment of a stream with a much, higher nicotine concentration.
These trials will begin mid-June.
-~i uiid Absorber Nicotine Separation: Tests were conducted by Chemical Researchh
on selective separation of' nicotine from the liquid absorber effluent with the
objective of retaining flavor compounds while removing the nicotine. Reverse-phase:
separation fractions were generated using both C-M silica, gel and XAD-4
absorbents. The recovered neutral fractions were applied to: extracted filler at two
levels, representing, 70% and 100% recovery. The resulting, batches of filler were
provided to Flavor Development for evaluation against control extracted product.
- Stem Utilization:
Citric Alcid (CA) Treated Stems: Pilot plant test runs were completed for the
purpose of generating stem samples from d'ifferent points in, the process. The sample
points were selected to isolate analytical and subjective differences caused by the
citric acU alone, exposure to CO2 at temperature,, and transfer of components from
the filler during extraction. The Analytical Research Division, has begun extensive
analysis of the stem samples, and RL pilot sheets made from the stems. In addition,
Flavor Development is conducting subjective analyses.
2: Prgject Bo ld: All initial monadic POL tests have closed out These tests (0265, 0526,
0530) used the MUL-type blend w/50% BLDET (241), Blend 240 was selected as an
improvement over the initial Blendl 241. Prototypes have been made using this blend
to evaluate new flavor systems. Based on analytical and subjective evaluations,, a
model will be selected from this series for POL 0268 (primary scheduled for the week
of 6/4).
The Leaf Department is redesignang, Blend 240, (removing RCB & RLB) to improve
puff count and increase subjective response.
A request has been submitted to the Semiworks for a, I mg BOLD model using an ultra
high efficiency polypropylene/CA filter in, an 18/9 mm dual configuration.
Parliament-type filters were received from Stockton Street factory for use in the
development of a 1 mg BOLD model. A request for cigarette-making was submitted: to
the Semiworks.
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Concentric filters for & 1 mg, BOLD model were designed. These concentrics have
ei ther a paper core or paper periphery in, combination with 1.6/41000 tow. These
designs have been forwardcd to American Filtrona for filter making, and filters are
currentNy being, manufactured..
Project 605 modcls with SCS Ill filters; hole-in and hole-ou4 were subjectively
evaluated by Flavor Development. Results indicate the SCSS filter with the hole toward
the smoker imparts a higher impact while holding filtration efficiency constant. This
work will have application to 1-2 mg prototypes.
3. Low Sidestream ProPram:
- Trim V: Superslims cigarettes were made in Louisville using, papers coated with
acids for subjective improvement. Cigarettes containing succinic acid on the outer
wrap or inner liner did not show a subjective advantage over control Superslims
cigarettes. Pimelic acid on the outer wrap gave a, slight subjective improvement.
There were no significant differences in analytical data or sidestream, rediuctioni for
these cigarettes. Additional work on Superslims is planned~ with additional additives.
- Lotus; The Sidestream Panel' evaluated a number of cigarettes with a, reduced level of
mono-potassium, phosphate combined with different acids on, the high basis weight
paper. Malonic acid with mono-potassium phosphate continues to be the leading
candidate for subjective improvement. This paper is ttieing, evaluated with several
new aftercuts.
- Sidest'rearm `'isibili'ty: A matrix test of variations in the levels of malonic acid and
mono potassium, phosphate on: the heavy basis weight paper showed~ increases in
sidestream reduction with ani increase in acid or phosphate. Acid levels up to 5%
and phosphate upto 10% of'the weight of the paper were used, with the subjectively
preferred model having 7.5% phosphate and 3% acid. It gave 75% visibility
reduction. The highest total additive level gave 84% reduction.
The models made for Ambrosia II gave 51-61% visibility reduction for 24:8' mm king
size cigarettes, andi 56-68% reduction for the 24.0 circumference, 100' mm cigarettes.
The heavy weight paper (63g) gave higher reductions in all cases thani the medium
weight paper (45g).
4. Prniect A'mbrosia:
- Ambrosia l: CR-2910 is being consideredl for use in sideseam adhesive. A small-
scale batch wa:s prepared at National Starch; initial maker trials were cond'ucted~ and
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cigarettes are being evaluated. Analytical investigations are continuing to determine
the~ cause of batch-to-batch variability of adhesive containing, Aromatek-150. Init2al'
results indicate that Aromatek-150 is polymorphic ini structure with different
solubility for each crystalline : structure.
Cigarette saanples were made with the above compounds in, the sideseam adhesive:
Ambient and accelerated agedl samples from these trials have been submitted for
analysis of the flavor compound on the cigarettes.
Internal aroma testing, of 100% blend components was completed. Due to poor
replicability, few differences were found. Oriental was found to be very irritatnng,
have a high d'istinctive odor, and was overall unacceptable. A request for
construction of an indoor odor chamber has been made, an area in the OC Computer
room has been providedfor this purpose, and plans are now being drawn up by
CRSS. Peryam and Kroll will~ be conducting reproducibil'ity studies in their
chaunbers to determine whether we could make use of their services at this time:
- Arrsbrosia li: Sixteen 100 mm, 24.0 circumference prototypes using two basis weight
papers, two levels of Aromatek 245 and charcoal/non-charcoal filters have been
made. Samples were submitted for C:I: analysis and sidestream visibility reduction.
Fifteen 85 mm, 24.8 circumference models have ! been made using materials similar
to the 100 mm models. Analytical and subjective evaluations of these models are
being, used! to determine POL monadic tests in June/July. Twelve samples (85 mm-
100 mm) have been placed in ambient and'hot/dry conditions for a period of six
days. These samples have beeni submitted' for analysis of Aromatek 245 on paper.
5. Marlboro M~~odsfc~ation.~.
F L Ti 'l Descri tp ion. Status
0336 83 mm w/21 mm filter In the Field
0337 83 mm wi127 mm filter In the Field
0330 80 mm with 1.6 tar/puff Manufacturing in Progress
0331 84 mm with 1.6 tar/puff Manufacturing in Progress.
POL 3635 (11!Iarlboro~ 83--like ani 80 versus Marlboro 83--like an 84) was completed
No significant differences were seen on any scale.
O
N
N
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6. Marlboro Reduced Ingreduents, ,
Cigarette models using the current Marlboro System and two test blends have been
subjectively smoked. One of the test models contained a new sheet' material and a new
casing. The second test model contained regular blend with a new casing system.
Subjective evaluations indicated that the test blend containing the new sheet material
was subjectively different from the control. A new sheet material is being made in the
pilot plant. A large-scale run using the new sheet material is scheduled for the week of
June 4, 1990, with cigarettes to be made the week of June 11, 1990.
7. Marlboro Standardizatfon:
8.
Subjective evaluations have been completed on Marlboro pickup of Apri123, 1990. A
final report wilQ be issued when analyticals have been completed. A plannang, session
was held on May 16, 1990 to schedule the Standard VIIT run. Current plans are to
make the standard~ run the week of August 13, 1'990!
Miscellaneous Marlboro: Startup of the new evaporator system oni Line3 at Park 500
is scheduled for midLJune. Plans are in progress to make control and test Marlboro
fillers with RL's from Park 500 at the MC for POL 3634. A solubles level study is in
progress to determine the subjective influences of higher sollubles to be available from
the new system.
9. Marlboro Monadic Panel: POL's 0332 (Marlboro~ 83 mm box-like an 84 mm)and
0333 (Marlboro 83 mm box-like an 80 mm) were completed. Both prodlucts fell within
acceptable regions fbr all three smoker groups (Marlboro, Winston, and Cmel).
POL's 0334 (Marlboro 83 mm soft pack-1ike an 80 mrn) ~ and 0335 (Marlboro~ 83 mm
soft pack-like an 84 mm) are in the field. Scheduled close out date is May 30.
10. Other Monadic Research:
- 1100, mm Nonmenthol Monadic Panel: Six more tests have been requested: 0531
(Virginia Slims Lights); 0533 (Ambrosia I at 24 mm), 0534 (Amhrosia, I at 23 nm);
0535 (Ambrosia l!I,/LSS), 0536 (Ambrosia 1J,/Aromatek 245), andl 0537 (Ambrosia
II/LSS/Aromatek 245):
POL 0522 (B&H) ! has cliosed out and t'he results are being analyzed.
- 85' mmi NOnrnenthol Monadic Pane9: POL's 0251 (Winston Lights), 0256 (D+iatural
8) and 0265 (BOLD) are in the field. All will close out by June l.
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-10iLmmiMenthol Monadic Panel: Nowv (0605), Chelsea, (0635), and an Ambrosia
model wi th flavored adhesive (0634) closed. Results for Ambrosia and'i Chelsea
showed' no significant difference on liking, or amount of menthol. However, Chelsea
wa:s rated higher thani Ambrosia on strength. Results for Now showed that it was
rated significantly higher than Salem Ultra Lights on liking, strength, andd amount of
menthol.
Carlton (0604) and~ a menthol version of Parliament Lights 100 (0636) closed. Resulks
for the total' panel' showed that Parliament Lights menthol was rated similar to Salem
Lights on~ liking and was rated' significantly higher than Marlboro Lights. Carlrcon
was rated lbwer than Now on liking.
Requests for a 23 mm Ambrosia I model (POL 0644) and several Ambrosia lIi models
(0643' - LS S,, 0646 - Aromatek 245) have been submitted.
- 85 mm Maenthiol Monadic Panel: POL's 0405 (Merit), 0409 (Marlboro Lights) and
0431 (Salem Ultra Lights) were completed. Results showed' no significant difference
between the Salem Ultra Lights tested in 0431 and~ the Salem, Ultra Lights tested in
0403. Both Merit and Marlboro Lights were rated similar to Salem Lights.
Results for Parliament Lights Mentholi 85' mmi (0435) showed that the cigarette was
rated lower than Merit, Marlboro Lights, and Salem Lights oni liking by the total'l
panelL An experimental with 1.1 tar/puff and .08 menthoWpuff was rated similarly to
Merit, Nlarlboro Lights, and Salem Lights. Three experimental cigarettes with hzghi
menthol levels have performed well on this panel (1.4J.09, 2.3/:09, and 1.1J.08)i
POL's 0441-0443 (245/LSS, LSS, & 245) have been requested under the Ambrosia lT
program.
11. Other External Testing: POL 3636 (Cambridge - old' blend versus new blend) closed.
Results for Cambridge smokers showed~ no significant difference between the blends
on l2king, and preference, although the new blend was rated more favorably than the old
on mild taste and cool smoking. No differences were found for Doral smokers. A
multivariate analysis of variance showed no significant differences between blends~:
POL 3637 (Marlboro versus Marlboro with RCBX2) ~ is in the fie1d, Close out date is.
June 7.
POL 71'9'1 (Ambrosia, 19 mg versus Ambrosia 1111 mg) 1 has been requested.
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12. Marketiag ResearchIl-IT Competitfve Testt'nE,
- POi Competitive Testing
POL 0903' - B&H Lights 100 mm versus Winston Lights 100 mm.
The B&H Lights 100 mm smokers rated their own brand higher on
mild taste, goo& taste, coof smoking, good aftertaste, and liking.
They rated the Winston Lights 100 mm higher on harshness, easy
drawrr,, and dry taste. T'he Winston Lights 100 mm smokers rated the
B&H Lights 1001 mm higher on mild taste. They rated their own
brand! higher on, easy draw.,
POL 0906 - B&H DUL Menthol 100 mm.versus Salem U1tra, Lights 100 mm.
Status: Thetest has closed out. Results are being analyzed.
POL 0905' - Merit 100 mm versus Winston Lights 100 mm..
Status: In the field Scheduled close our date is May 30.
POL 0904 - Cambridge Lights 100 mnn versus Doral Lights 100 mm.
Status: In the field. Scheduledclose ourdate is June 21.
POL 0907 - Merit Ultra Lights Menthol 85 nun versus Salem Ultra Lights 85 mm.
Status: In the field. Scheduled'I close otit date is Jnne 27.
The following tests were released for shipment during May, 1990:
Competitive Tests
Shignaent Date
HTI 1722 Marlboro Lights Mentho185 versus 5/18/90
Kool Mfi1ds 85
HTI 1290 Marlboro Lights 85 versus 5/2.1/90.
Winston Lights 85
Marketing Research: HTI Se:auential Monadic
HTI 4'841/10160 Biucks Lights 85 mm versus 5/8/90
Winston Lights 85
HTI 4842/10161 Bucks 85 mm versus 5/8/90
Winston 85 mm
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HTI 2533/10175 Marlboro 85 versus 5/30/90
Came185
The follbwing tests are scheduled for shipment in June:
Competitive Tests Target Ship Date
POL 0912 Wirginia Slims Ligttts Menthol versus
Salem Slims Lights 100 6/11/90
POL 0917 Marlboro 80 versus Camel 80 6/18/90
HTI 4845 Cambridge 85 versus Dora185'
HTI Secti4ential Monadic 6/18/90
HTI 2526 Marlboro 80 versus Camel 80 6/4/90
HTI 2532 Marlboro 80 versus Came180 6/11/90
13. Proiect Saunar Three prototypes for the GCC area (4 mg tar) were subjectivel+y
evaluated by Flavor Development versus a Saudi Barclay. Two models (duaI
concentric/1.6/41000 CA; and mono paper) achieved parity, whilb the third model'
(dual SCS-III/1.6/4'1000) was preferred. Three earlier prototypes were remade to
adjust deliveries and' are currently being analyzed. These have filter systems of duaI
concentric and carbon-on-1.6/41000 CA, dual 1.6/41000 CA/paper, and! dual Filtrona
Astra/1.6/41000 CA. The best candfdates will be forwarded to EEMA for evaluation.
Two models for Japan (5 mg tar) were s bjiectively evaltiated versus a Japanese
Barclay and both were preferred. These had filter systems of dual concentric%arbon-
on-1.6/41000 CA; and dual SCS-IIIVcarbon-on-2.6/42 00 CA. These have been
subnnitted to Japan Product Development for evaluation.
141. Project Grain: Further Flavor Development panel tests of Cambridge cigarettes
showed no obvious differences for controll versus sonolated test aftercut with & 30%
reduction in alcohol. A POL test has been requested to confirm the results on
Cambridge cigarettes.
Subjective evalluatibns are in progress on Cambridge aftercuts to test a range of
alcohol reductions up to 40% without addition1 of water to compensate for volume.
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15. ViWnza Slims Superslims: Flavor work continues in ani effort to reduce the paper-
type taste of the current products. Eight new systems are currently under evaliuationL
16: Bran;d Extensi+ons and Modifications: Marlboro 80 & 83 mm Menthol FTB - Models
produced and submitted to Richmond Panel for subject2ve evalluatuonL
Alpine 83' mm Menthol - Initial analytiical results showed low level of' menthol inn
snioke. Scheduled for remake in the Semiworks the week of 6/11/90:
Virginia Slims KS wiith, 20.0 nun, and 23.0 mm circumference - Designi work
completed for FF, Lights, and U.L. models. Requests issued to Semiavorks and will
be produced the week of 6/4/90.
17. FiZter Research and Develn,pment:
- Concentric Filters: MEGA lonk-a-lilce test (concentric) and control (CA mono))
models were made with MFUL filler. The. test delivered 8,8 nng, of tar and the
control 8.6. These models were evaluated for subjective quality by Flavor
Development. The only comments from the ! panelists were that the control had
slightly increased impact and was more peppery than the test.
Samples of F1R-produced Mega cigarettes with CA mono and the current concentric
filter have been received. The cigarettes are currently being analytically tested!
'T'he :F1~vor Development panel will subjectively evaluate them after CI testing.
- Web ~ Filter Develo mn t'. Sample webs were produced at the Universiity of Maine
using, 75% 1/8" cut CA staple and 25% softwood fiber. Varnious refining levels
were evaluated and CMC and PVA binders were used to improve elongation.
Sample bobbins are currently being evaluated for filter-making machinability, and
cigarettes will be produced for analytical and subjective evaluatson.
Characterization of the most recent Kimberly-Clark produced CA Web from
Celanese is progressing. Capabilities and variability measurements have been
completed on each width. Within & bobbin the RTD~ coefficient of'variation has
been improved compared to previous CA web samples. Cigarette models using
MFLTL filler have been produced for comparison to ~PM Web, paper and CA tow.
Sample filters from Dexter's latest CA web were received from Celanese. The
standard model (20% fibrets + 76%, staple + 4% PVOI-I), is being compared to a.
Dexter test model'which has a low level' of wood fiber included to ianprove wet.
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