Product Design
Technology Assessment Status Update (May 29, 1992 - K.W. Smith)
Abstract
Assesses problems and potentialities of various development projects. Includes sections: "NTF (Natural Tobacco Flavor); Direct by products additions (DBA); G7-25; Sugar nicotine balance; Increased humectant levels; Modified MTT; High temperature G7 extract; Reaction (K-1008) type flavors; Ammoniated tobacco (flue cured); Heat treated burley; Washed/denitrated carbon treated K stem G7 sheet; Heat treated burley; High temperature G7 extract sheet; Modified MTT flavor system; Alkalized cocoa; Sugar nicotine balance; Natural Tobacco Flavor (NTF); Increased humectant levels; Reaction (K1008) type flavors; Ammoniated tobacco (Flue cured); [and] High temperature extract G7 SED results". Expected benefits of almost all of the aforementioned projects/tests include smoothness and harshness improvement.
User-Contributed Notes
Fields
- Author
- Smith, K.W.
- Hypothesis
- Free Nicotine
- Nicotine transport, transfer, and uptake
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.- Use of filters, paper, and ventilation
Modification of tobacco products through use of filters, paper, and ventilation, and measuring effects on dependence, behavior, and toxicity.- Use of additives
Modification of tobacco products through use of additives and measuring effects on dependence, behavior, and toxicity.- Use of tobacco processing/ blends
Modification of tobacco products through changes in tobacco processing and use of blends, and measuring effects on dependence, behavior, and toxicity.- Introduction of new/unconventional products
Research and development of novel nicotine delivery devices and experimental tobacco designs.- Mainstream constituent yields
Modification of selected mainstream smoke constituents in response to health concerns.- Behavior Targeting
Cigarette's effect of enhancing/mitigating specific behaviors - Nicotine transport, transfer, and uptake
- Keyword
- Total particulate matter (TPM or Tar)
- Volatile nicotine
- Maillard reaction
- Volatile nicotine
- Additive
- Aqueous Turkish extract
- Asparagine (l-Asparagine Monohydrate)
- Carbonyls
- Cocoa (Chocolate) (Cocoa Shells, Extract, Distillate and Powder)
Composed of nearly 400 identified chemical substances as of 1967- DAP
- Fructose
- HFCS
- High fructose corn syrup
- K-1008
- Licorice (Licorice Fluid Extract, Powder, and Root)
- Natural Tobacco Flavor
- NTF
- Pentanidione
- Sucrose (Sugar)
- Cocoa derivatives
Produced by fermentation, defatting, hot pressing, grinding, roasting, peeling - Asparagine (l-Asparagine Monohydrate)
- Smoke Constituent
- Nicotine
- Volatiles
- Hydrogen cyanide (HCN)
- Nitrosamines (N-nitrosamines)
- Volatiles
- Design Component
- B3
- B9
- BP7
- Burley casing
- Casing
- CRES
- Flue-cured tobacco
- G7 (RJR @reconstituted_tobacco)
- G7-25
- G7-9
- Heat treated extract G7 sheet
- HTE
- KRES
- Reconstituted tobacco
- Turkish Blend (TB)
- C30-A
- B9
- Prototype
- FFLT
- Full Flavor Low Tar
- RU/SB Lights
- Ishmir ZA extract prototypes
- Full Flavor Low Tar
- Operation/Project
- Camel RU (Camel Special Lights)
- Nicotine RSM (Nicotine Response Surface Methodology Study)
RJR study conducted in late 1980s / early 1990s to test acceptability of new experimental cigarettes- Super Smooth Project
- Nicotine RSM (Nicotine Response Surface Methodology Study)
- Named Organization
- IFF
- R.J. Reynolds Tobacco Co. (Cigarette manufacturer (Camel, Winston, Doral))
Cigarette manufacturer (Camel, Winston, Doral)- AVOCA
- R.J. Reynolds Tobacco Co. (Cigarette manufacturer (Camel, Winston, Doral))
- Technology/Method
- QVS
- Quantitative Variable Screening
- MTT Flavor System
- Flacing
- Denitration
- REST
- Quantitative Variable Screening
- Subject
- additives
- Ammonia (Additives)
- Ammoniation (Technology)
- Blends (Design)
- Humectants (Additives to maintain moisture)
- Licorice (Additives)
- Reconstituted Tobacco (Design)
- Smoke Constituents
- Smoke Delivery/Transport (Measures)
- Smoke pH (Measures)
- Smoothness/Harshness (Effects)
- Smoke Nicotine (Measures)
- Sensory Effects—Taste (Effects)
- Ammonia (Additives)
- Brand
- BV
- Winston KS
- Winston SB
- Winston SB Lights
- CAMEL LIGHTS
- MARLBORO LIGHTS
- Winston SB PGT
- Camel Lights 83
- Winston KS
Document Images
* Heat Treated Burley:
Description: High temperature treatment (300 - 325°F Dryer Temps) of cased
Burley at +28% moisture results In milliard reactions that give
added aroma, taste, and/or smoothness.
-Status: Testing has demonstrated feasibility and required tobacco
temperatures and moisture. Manufacturing trials have been run
that identified appropriated process conditions for production of
heat treated burley. Control and test products have been made
from the burley produced In manufacturing (both straight burley
cigarettes and blended FFLT cigarettes. The blended FFLT
cigarettes are tQ be mailed out to a Qoantitative Variable
Screening consumer test with results expected In early July.
Initial informal evaluation of straight burley and blended cigarettes
by Brand Development Staff indicates no significant taste
difference for either the straight burley or blended cigarettes.
Next Steps:
Consumer test results of heat treated prototypes (July).
Complete internal sensory evaluation of straight burley and blended
cigarettes (June-July).
Complete analysis and review of chemical parameters (June-July).
Conduct stack emission testing to permit manufacturing operation of
process (June-July).
WINSTON SB prototype with Heat Treated Burley and new Casing PGT
consumer test results (late Aug 1992)
(11)
WASHEDfDENITRATED.CARBON TREATED K STEM G7 SHEET
1. TECHNOLOGY DESCRIPTION:
A. Burley Stems to be used in production of G7 are first washed with water, they
are then extracted In hot water and nitrates are precipitated out of the extract.
The denitrated extract is then treated with carbon, concentrated and reapplied
to the G7 sheet.
II. EXPECTED BENEFITS:
A. Smoothness/harshness improvements
B. Cost
C. Personal Concern `
111. BASIS FOR BENEFIT EXPECTATION:
A. Qualitative testing by Super Smooth Project Group suggests that this sheet is at
may have enhanced smoking properties.
B. Analysis of initial product produced with this sheet shows significant reduction in
carbonyls and HCN. Carbonyl reduction might be expected to reduce
harshness of smoke.
IV. BENEFIT APPLICATION:
A. Harshness reduction should be directly applicable to those FFLT products that
have smoothness/harshness improvement as key product development
direction.
B. Reduction in levels of carbonyls, HCN and nitrosamines, if reaiized , might allow
us to realize cost benefits on savings brands through higher inciusion of burley
stems with out significant taste trade offs increase In these substances.
V. DEVELOPMENT PLAN:
A. The Super Smooth Project Team will conduct QVS consumer testing of FFLT
prototypes using this sheet: (May 92)
B. Internal sensory analysis will be conducted on these same products. (May)
C. Preliminary cost and scale up estimates: (June 92)
D. Based on the results of the QVS testing larger consumer testing in appropriate
product styles (full priced or savings segment) will be conducted. (3rd-4th Qtr)
V:. FINANCIAL COST ANALYSIS: - -
A. Detailed cost analysis has not been performed. Existing facilities can produce
limited amounts of this sheet. _
VII. OPPORTUNITY COST ANALYSIS:
A. R&D resources required for evaluation of this process are moderate. Primarily
these include G7 pilot plant time and resources, analytical services and
consumer testing resources.
B. Scale up of this process will take significantly more resources and would be In
competition with other new sheet and tobacco processing projects.
VIII. TIMING:
A. Initial consumer test resutts (QVS): (June 92)
B.
C. Larger scale consumer testing:
Scale up dependant on volume needs: (3rd-4th Qtr 92)
IX. POTENTIAL PROBLEM(S) EVALUATION:
A. Supportable volumes limited
B. Cost for facilities
X. RELATIVE IMPORTANCE:
A. For smoothness/harshness improvements, preliminary evaluations indicate that
this project may have limited benefit. Depending on the degree that these
attributes are shown to be improved In quantitative testing, this project may
have more direct application to cost savings or personal concern.
XI. HOW LIKELY IS ACHIEVEMENT OF EXPECTED BENEFIT?
A. Smoothness benefit is uncertain and may be in significant.
B. If nitrosamine reductions are realized then costing of the process for increased
inclusion of Burley Stems could have significant cost benefits.
XII. COULD OTHER APPROACHES PROVIDE THE SAME BENEFITS?
A. Expected reduction in discussed smoke components are currently expected
from any other technology being evaluated for Smoothness/Harshness
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I. TECHNOLOGY DESCRIPTION:
A. High temperature treatment (300 - 325°F Dryer Temps) of Burley Tobacco
cased with High Fructose Corn Syrup (HFCS) at +28% moisture results in
maillard reactions that produce new/unique flavor and aroma compounds.
B. High temperature may also drive off some of the volatile nicotine in the Burley
Tobacco and there by reduce the amount of volatile nicotine in smoke of the
blended cigarette.
II. EXPECTED BENEFITS:
A. Increased smoothness and reduced Harshness
B. Added pack aroma
C. Added Flavor
III. BASIS FOR BENEFIT EXPECTATION:
A. Internal sensory evaluation as well as qualitative focus groups indicate that this
type of Burley Tobacco may offer smoothness/harshness benefits as well as
improved acceptance.
B. Both sensory evaluation and head space analysis demonstrate that the heat
treated burley tobaccos have significantly more aroma than our normally
processed burley.
C. Many of the compounds expected to be formed by the Maillard Reaction should
have flavor and aroma properties different from the original starting materials.
IV. BENEFIT APPLICATION:
A. This approach may offer benefits for full flavor, full flavor low tar, and ultra light
products. This approach is applicable to full priced and savings segment
products as well.
B. Product application will be dependent on the product specific attribute
movement provided by the technology and the specific development needs of
new and existing products.
V. DEVELOPMENT PLAN:
A. Testing has demonstrated feasibility and required tobacco temperatures and
moisture. Problems with Proctor Swartz dryer and Pilot Plant casing operations
delayed testing for several weeks but have now been resolved. Mike Dube will
mail out prototypes with new casing and heat treatment on May 6 (21-49 FFLT
ex-Savings).
B. A team of R&D and Manufacturing Staff designed a test that was run at
Whitaker Park 4/7/92 to determine if reasonable manufacturing operating
conditions will produce desired product. Preliminary aroma evaluation of these
test tobaccos indicate that manufacturing can produce the desired heat treated
burley at normal operation speeds and tobacco flow rates (i.e. 10 min dryer
retention time) using dryer temperatures of 300-320°F. Subsequent work at
Whitaker Park has also shown that reordering of the heat treated tobacco can
be accomplished with app`ropriate settings of existing equipment.
C. The tobaccos from the whitaker park run will be used for analytical and sensory
testing. We will prepare control and test products from manufacturing
produced materials and evaluate Internally in straight burley FF configuration,
and in a FFLT blended cigarette configuration. (April-May)
D. Prototypes will also be produced from the Whitaker Park Heat Treated Burley
for consumer testing. A Quantitative Variable Screening (QVS) test is planned
for these products in Mid June.
E. Extensive analytical evaluation of the heat treated and control burley tobacco
will be conducted to characterize the key effects of the process.
F. Additional manufacturing runs will be made at Whitaker Park to allow setting of
process specifications. (April-Aug)
G. An emissions test will be conducted to quantify and obtain, if necessary,
environmental permits for the process changes. (April-July)
H. Additional heat treatment testing with other types of casings (i.e. sucrose
instead of fructose) will be evaluated In second and third quarter.
VI. FINANCIAL COST ANALYSIS:
A. Detailed cost analysis has not been performed. Initial indications, assuming no
special emissions control equipment, are that there will be minimal cost impacts
(i.e. production rates will be same as current with no new capital equipment, no
added man, power, and no special inventory or handling procedures). The only
up charge will probably be increased stem usage for higher dryer temperatures.
The cost of this is not clear as there is excess stem capacity.
'VII. OPPORTUNITY COST:
A. Significant R&D and Manufacturing resources are being committed to the
development, testing and implementation of this technology.
B. Large amounts of-laboratory time and manpower will be used for the extensive
evaluation of this technology.
C. R&D Plant Time and resources will be required for production of straight grade
and blended cigarettes for Internal and external evaluations.
D. SED resources will be used for evaluation of straight burley and blended
cigarettes.
E. Consumer testing, QVS an`d later PGT(s), will be required for evaluation and
Implementation of this technology.
VIII. TIMING:
A. Initial consumer screening planned for Mid-June mail out. If results are good,
then this technology could be PGT tested for WINSTON SB in Late August.
B. The required process specifications and resolution of environmental issues can
be resolved well before the end of third quarter 92.
IX. POTENTIAL PROBLEM(S) EVALUATION:
A. Environmental emissions of nicotine and other hydrocarbons may be
significantly increased by this process. This could require re-permitting of
production facilities and additional emission control equipment. The extent of
this problem, if any, will be evaluated in second quarter.
B. There appear to be no significant problems with equipment and process
capabilities in manufacturing. There are no inventory support problems. Heat
treatment will create additional blends and sub blends and therefore may
exasperate blend proliferation and bulker shortages over the short run.
C. Use of HFCS will require some special handling (manual manipulations) in
manufacturing until we fully convert to HFCS in third quarter.
X. RELATIVE IMPORTANCE:
A. The potential benefits of Heat Treated Burley (i.e. smoothness, added flavor and
improved pack aroma) if fully realized, could be extremely valuable to our efforts
to produce superior products.
XI: HOW LIKELY IS ACHIEVEMENT OF EXPECTED BENEFIT?
A. It is highly likely that the heat treatment process produces a burley tobacco that
is different from our current. However, additional evaluation is required to
determine the degree to which this technology delivers the expected benefits In
blended cigarettes and to what extent this material can impact the performance
and taste attributes of the`se cigarettes with key consumers.
XII. COULD OTHER APPROACHES PROVIDE THE SAME BENEFITS?
A. There are several other technologies as well as modifications to the burley heat
treatment approach that may offer similar benefits. However, these other
approaches should be viewed as additive or incremental to the proposed
process at this time. Planned work should lead to Identification of best options.
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I. TECHNOLOGY DESCRIPTION:
A. G7 extract is raised to significantly elevated temperature (e.g. 300°F for 10 min.)
In a pressurized vessel prior to application to the sheet. The heat treatment
process drives reactions that produce flavor and aroma compounds not present
in our current sheets. This process does not use DAP.
F
II. EXPECTED BENEFIT
A. Enhanced Pack Aroma
B. Improved Smoothness and Harshness
C. Added or Enhanced Flavor
Ill. BASIS FOR BENEFIT EXPECTATION:
A. Initial screening on lab scale products indicates significant changes in the
aroma, flavor and smoothness of heat treated extract sheet.
B. Head space analysis supports the sensory aroma differences.
C. Analytical evaluation of extracts confirms that Maillard type reactions are
occurring.
IV. BENEFIT APPLICATION:
A. If expected benefits are realized, then this technology could have important
applications across all tar categories and price ranges.
B. Product application will be dependent on the product specific attribute
movement provided by the technology and the specific development needs of
new and existing products.
V. DEVELOPMENT PLAN:
A. Heat Treated Extract Sheet was produced In a small batch mode in late March
using a "bomb" on loan from Avoca. This sheet was used to produce Full
Flavor and Full Flavor Low Tar prototypes in the R&D Plant. (April 6)
B. The chemical, smoke and sensory properties of the test and control products
will be evaluated. (April 92)
V. (CONTINUED)
C. Data on the chemical properties of the heat treated extract from the batch
process will be collected for comparison to larger scale processes to be looked
at In the future. Additional flavor development work will also be conducted on
the cigarettes produced in the April 6 pilot plant run.
D. Assuming positive sensory properties for the products made with the heat
treated extract sheet, then the G7 Pilot Plant will be asked to install the required
equipment to produce this sheet in line. (April-May)
E. The pilot line will then be used to produce sheet for QVS consumer testing.
(June-July)
F. Given positive results from QVS, we will incorporate heat treated extract sheet
into larger scale consumer testing. (3rd-4th Qtr)
G. If positive results are confirmed in consumer testing, then requests will be made
to Tobacco Processing to modify G7 facilities to enable production of this sheet.
(Request in 3rd-4th Qtr., Modifications to take 3-to-9 months)
VI. FINANCIAL COST ANALYSIS:
A. Detailed cost analysis has not been performed. Initial indications are that G7
plant modifications in the range of $ 500,000 would be needed for initial
production. Additional expenditures, up to about $ 2,500,000 could be required
under a worst case of being able to heat treat extract for all G7 produced.
B. Added cost to the G7 produced should not exceed 10 per pound.
VII. OPPORTUNITY COST:
A. Moderate R&D resources required to complete development, testing and
evaluation of this technology.
B. Significant commitment will be needed from the G7 pilot plant to install required
modifications to allow us to complete consumer evaluation by end of year.
C. Consumer testing resources, QVS (3-4 cells) and PGT (2-4 cells) will be
required to determine the benefits of the technology and to justify required
expenditures for plant modifications.
