sample="quota" bates="2001115061" isource="pm" decade="1980" class="ui" date="19840630" THIS REPORT IS CONFIDENTIAL TO THE BUSINESS OF THE COMPANY: IT SHOULD BE CAREFULLY HANDLED, IS NOT TRANSFERABLE TO ANOTHER INDIVIDUAL, AND IS NOT TO BE PHOTOCOPIED. If the report has served its purpose and is no longer needed, please return it immediately to the Central File at the Research Center for record keeping purposes and destruction. Accession Number: 84-210 Copy Number: 4 Issued to: PHILIP MORRIS U S A RESEARCH CENTER RICHMOND, VIRGINIA MONTHLY PROGRESS REPORTS Period Covered June 1-30, 1984 Date Issued July 15, 1984 DISTRIBUTION Dr. M. Hausermann Dr. J. Charles Mr. L. Meyer Dr. T. Osdene Mr. K. Burns Mr. F. Daylor Mr. P. Gauvin Dr. R. Jenkins Mr. D. Knudson Mr. B. Kosakowski Mr. W. Kuhn Mr. B. LaRoy Dr. C. Levy Mr. C. Rowe Dr. E. Sanders Mr. F. Watson Mr. M. Waugh Dr. J. Whidby Mr. J. Wickham Ms. C. Bright Mr. B. Daughtry Ms. B. Handy Dr. R. Kornfeld Mr. M. Rosenberg Mr. D. Watson Mr. W. Claflin Dr. R. Ikeda Mr. A. Lilly Mr. H. Merritt Mr. R. Carpenter/Dr. R. Pages Mr. B. Fischer/Mr. J. Osmalov Dr. A. Kallianos Mr. G. Keritsis Mr. H. Spielberg Dr. D. Lowitz Ms. S. Hutcheson Mr. R. Bass Dr. G. Bokelman Mr. R. Comes Dr. R. Cox Dr. R. Dwyer Dr. W. Edwards Dr. C. Ellis Dr. D. Faustini Dr. R. Ferguson Mr. D. R. Fox Mr. R. Gaudlitz Mr. G. Gellatly Dr. B. Good Ms. B. Goodman Mr. H. Grubbs Dr. E. Gullotta Mr. W. Harvey/MR. G. Vilcins Dr. C. Higgins Mr. W. Houck Dr. R. Izac/Dr. D. McRae Mr. C. Kounnas Mr. C. Kroustalis Mr. H. Lanzillotti Dr. J. Lephardt Mr. S. Long Dr. B. Losee Dr. R. McCuen Mr. C. Moogalian Mr. J. Nepomuceno MR. R. H. Newman Mr. W. Nichols Dr. R. Pages Mr. A. Robinson Mr. F. Sherwood Dr. J. Swain Ms. S. Tafur Dr. D. Teng Ms. P. Thomas Mr. R. Uhl Mr. A. Warfield Mr. C. Bates/Mr. M. Christy Dr. M. Bourlas Mr. H. Daniel Dr. W. Gannon Mr. T. Goodale Mr. R. Heretick Mr. A. Holtzman Mr. Art Palmer Mr. A. Pasquine Mr. F. Resnik Dr. R. Seligman Dr. L. Sykes Mr. K. Wood/Mr. T. Newman Dr. R. Dawson Dr. A. Wolf Central File (2) TABLE OF CONTENTS [By Product Number or Subject] 1. Product Development 1990 2100 2105 4009 4010 4015 4020 Burley Flavor Hercules Oriental 2. Process Development 0307 0400 1005 1307 1503 1801 1806 3. Applied Research 1702 1703 1704 1706 1708 1720 1725 1730 1901 1902 1904 2106 2500 2501 2505 2506 2515 2520 2525 2530 4. Research 1101 1620 1740 1750 1752 1754 1756 1758 6505 6902 6904 6906 6908 5. R&D Support Cigarette Testing Services CHARGE NUMBER: 1990 PROJECT TITLE: Blend Development PROJECT LEADER: C. M. Moogalian PERIOD COVERED: June, 1984 Special Tobaccos Objective To determine the character and possible utilization of tobaccos that are atypical of current usage. Status/Plans A. The tar target for project Hercules is 14 mg. Recently, three additional tar values have been requested for study - 10, 12, and 16 mg. We have designed modifications of the current Hercules prototype blend to accommodate the different tar deliveries. Cigarettes will be made by mid-July. B. The High Bright blend with a special flavor has been released for POL testing against Winston Lights (POL 4330). The tar delivery of the experimental is 10 mg. The blend currently contains Then Bright, expanded Bodied Bright, and expanded Dark-Air Cured. C. Two menthol levels (0.45, 0.60) on a 6 mg. blend with Dark Air-Cured will be POL tested against Salem Lights (POL 2086). Cigarettes have been made and approved for shipment. II. Project Tomorrow Objective To develop a prototype that is preferred 60:40 over Marlboro by Marlboro smokers. Status/Plans A repeat of POL 3138 has been requested. This is a test where the experimental was significantly preferred over 79-3 Marlboro. We are awaiting the availability of test smokers. Two test blends are being fitted with special aftercuts prepared by the Flavor Group. These models are in the process of being made in semiworks. III. Miscellaneous A. For Project Hamlet, a blend has been recommended following evaluation of several blends with special papers. B. In Project Premium, a series of blends with various Oriental levels have been evaluated, and one has been selected as the prime candidate. Additional blend work is in progress. C. For the improved Merit program, two promising blends are being remade in semiworks. D. For improved MUL. a test model with expanded Oriental has been released (POL 4316). E. In the Minor Brands study, B&H Multifilter nonmenthol was made using the Merit blend and casings and B&H Multifilter aftercut. Internal panel testing showed no difference between the test and the B&H Multifilter control. C. M. Moogalian /avm CHARGE NUMBER: 2100 PROJECT TITLE: New Cigarette Technology PROJECT LEADER: W. G. Houck, Jr. PERIOD COVERED: June, 1984 Project Data Objective To develop an adjustable tar cigarette product. Status Completed initial extended machineability trials. Completed internal menthol blend testing. Made cigarettes for menthol extended use testing. Completed initial test of tip turner. Plans Optimize tip turner July 1984 Complete pilot extended use menthol testing July 1984 Initiate large scale extended use testing 3rd Qt. 1984 Product optimization On-going II. New Package Designs Objective To develop new and novel package designs. Status Completed Phase II consumer testing of Hercules foil wrapped packaging. Planning alternate/improved designs for Phase II testing. Plans Complete Phase III testing Aug. 1984 Complete focus group testing of novel package designs Aug. 1984 III. Project Vangaurd Objective To develop a consumer acceptable nonburning smoking article. Status Several designs being explored (i.e., electrical heating, SWEPT devices, low/no tar burning articles). Negotiating a confidentiality agreement with GTE. Plans Explore new designs On-going Optimization of current ideas. On-going W. G. Houck, Jr. /avm CHARGE NUMBER: 2105 PROJECT TITLE: Filter Development PROJECT LEADER: W. A. Nichols PERIOD COVERED: June, 1984 1. Tobacco Extrusion (R. Thesing) Objective To develop an extruded foam tobacco product. Status Product: Additional data was obtained for firmness while smoking. When starch (Cereal binder) was removed and replaced with Dextran (microbial polysaccharide) the firmness improved. A special X-Pand-R starch from Staley improved firmness and reduced RTD. Lower binder levels were evaluated; 9% and 8% levels were found to reduce RTD from the normal 3.5 in to 2.8 in. Expansion at the die and product size was not adversely effected. Substitution of Natrosol (Hydroxyethyl Cellulose) for CMC did not improve firmness during smoking. Further testing is planned with reduced binder levels and substitution of Staley starch for cereal binder. Process: The "Plenum/dryer" has arrived from Rayco. It's equipped with a variable speed blower and can run with ambient or high temperature air. This equipment should provide an initial "set" to the surface of the rod for additional downstream handling. The unwind and take-up spools from Precision Engineering are in-house and being installed. The tension control unit is also with the spools. I. TOBACCO EXTRUSION Objective: Develop a process for extrusion of foamed tobacco articles. Status: Modifications to the feed hopper mechanism for the Wenger X-20 extruder are in progress. The plenum drier, take up roll and tensioning mechanism designed to handle the extrudate have been received and are currently being installed. The conveyor system for handling the extrudate through the microwave cavity has been completed; however, we are still awaiting receipt of the conveyor belt itself. Electrical wiring for these various units are currently being installed. Plans: Evaluate the handling and drying units and conduct tests to evaluate effects on product OV. II. FILLER BINDER Objective: Develop a process for applying a subjectively acceptable foamed binder to the tobacco filler rod at the maker in order to improve coal strength, reduce loose ends and allow for rod weight reduction. Status Recent improvements to foam binder application techniques have allowed extended runs on the maker with little or no build-up of binder on the maker. Binder formulations with only 0.25% foaming agent in the formulation were formed and successfully applied to the cigarette. More recent evaluation of hydroxypropyl cellulose solutions showed that this formulation can be foamed without the addition of foaming agents. The addition of DEXTRAN solutions to the cigarette was found to allow production of cigarette models with as much as 150 milligram tobacco weight reduction. Plans: Continue screening of various binders from both taste and process point of view. Evaluate application of foamed binders at higher make speeds. DRY FORMING Objective: Evaluate dry forming processes for making smoking articles and cigarette components from tobacco, tobacco by-products or non-tobacco materials. Status: A method for spraying the viscous binder solution onto the formed filler mat in a uniform fashion was developed using a high pressures spray system. Air laying the tobacco into the channels to create strips of bonded filler appear to increase the randomness of orientation of the various shreds. Plans: Continue development of techniques for air laying mats of randomly oriented tobacco filler. Identify other process specifications needed to develop a continuous dry forming operation. J. G. Nepomuceno /nb CHARGE NUMBER: 1801 PROJECT TITLE: Expanded Tobacco Development PERIOD COVERED: June 1-30, 1984 PROJECT LEADER: G. Gellatly I. CO2 IMPREGNATION A. Objective To find means of CO2 impregnation of tobacco without clumping. B. Status CO2 liquid spray impregnation trials in Cabarrus have been successful up to 22' be depth (300 lbs tobacco; target bed depth = 28-30' = 400 lbs). Tobacco clumping which occurred above 22' bed depth was attributed to CO2 liquid spray impact on the tobacco surface. Subsequent trials in the pilot plant using nozzles of different design have shown minimal tobacco compaction. C. Plans 1. Evaluate CO2 liquid spray impregnation of a 30" tobacco bed in Cabarrus using the preferred nozzle design identified in pilot plant trials. 2. Evaluate means of impregnation of bed depths greater than 30" in the pilot plant using the preferred nozzle design. 3. Complete evaluation of clump-free DIET in cigarettes. 4. Recommend a clump-free DIET process for factory installations following trials in Cabarrus. 5. Complete the modification of the pilot plant to eliminate the clumpbreaker and vibrabin and demonstrate DIET longs increase by spray impregnation and two-stage reordering. II. NOVEL PROCESSING CONCEPTS A. Flat Strip 1. Objective To evaluate processing of flat strip for improved filter length. 2. Status Filler length (Hamamatsu) from strip opened up by WET processing confirmed sieve analysis results that this filler was 25% longer than the control. Cigarettes (100%) made from this product showed reduced coal drop-off and loose ends but reduced firmness at the same weight. The reduced firmness of these cigarettes may be caused by the straighter nature of the product or the finer non-uniform cut width of the filler which may have been caused by the flatter strip requiring different cutter conditions. 3. Plans a. Repeat this trial with longer batches of product to ensure uniform cut width. b. Define a process to flatten strip preferably without overdrying. B. Cascade Reordering 1. Objective To evaluate a tobacco cascade reordering. 2. Status A vertical chamber with eight baffles, similar to the patented R. J. Reynolds flavor applicator, was installed at the 8 inch tower discharge for evaluation of "first stage" DIET reordering (to 8% OV). Seven low delivery nozzles were arranged to spray into the product free-falls between baffles. A equilibrated CV loss of 7 units resulted because of the short residence time in the equipment (3 seconds). Attempts to increase the product residence time by reducing the slope of the baffles caused bridging of the product between baffles and plugging of the equipment. A maximum residence time of under 5 seconds was obtained with no improvement in CV (30 seconds reordering time to 8% OV is required to avoid CV loss). Status: A collaborative study with Eddie Stagg was completed for the use of Ion Specific Electrodes in the determination of citrates in cigarette papers. It was determined that although the technique is satisfactory for the determination in papers (only those which have not been in contact with tobacco), ions present in tobacco cause interferences in the electrode when analyzing papers removed from cigarettes. C. Menthol Determination in Cigarette Packaging Materials (R. Kanipe) Objective: To develop a gas chromatographic method for the determination of menthol in cigarette flip-top boxes, foil wrappers, and paper labels. Status: A special report detailing the method for the determination of menthol in cigarette packaging materials has been completed and issued. D. Filter Efficiency by Spectrophotometry (F. Dawson) Objective: To evaluate a proposal to replace the gravimetric method with an automated photometric method for the determination of filter efficiencies for non-charcoal brands. Status: Studies necessary for the evaluation have been completed. It is recommended to continue use of the gravimetric filter efficiency method. A completion report has been issued. II. NEW BRANDS Three new brands were introduced during this month. A. Philip Morris is test marketing a new brand, Virginia Slims Lights Ovals 100 Box (plain and menthol). This cigarette has an oval shape and is similar in tar delivery to Virginia Slims Lights 100 Box (plain and menthol) cigarettes. Tobacco density calculations have been modified to accommodate this oval-shaped rod. B. Philip Morris is producing 25 cigarettes per pack of Marlboro 85 and Marlboro Lights 85 cigarettes per pack of Marlboro 85 and Marlboro Lights 85 cigarettes for test marketing in the Midwest and Northwest. The current per-cigarette price will be maintained, therefore, the new packs will cost approximately 25 percent more than the regular packs. Cartons will contain eight packs instead of ten. If the project is successful, packaging costs could be reduced. R. J. Reynolds and Brown & Williamson are currently marketing 25-count packages at discount prices in some areas. C. Lorrilard is test marketing Newport 100 (Box) and Newport Lights 100 (Box) in Connecticut. These new cigarettes are similar to Newport 100 already on the market. III. MISCELLANEOUS A. Nitrate Nitrogen Content in Domestic Cigarette Filler (C. Bright) Objective: To survey competitive cigarette brands for their respective nitrate nitrogen content in filler, reconstituted materials, expanded tobacco, and expanded stems. Status: A completion report was issued summarizing the 1983 data. The majority of competitive cigarette blends have nitrate levels ranging from 0.22 to 0.31%. Philip Morris continues to have the lowest nitrate nitrogen levels in its reconstituted materials. B. Filter Flare-up (B. Mait, G. Carter, R. Wiley) Objective: To add the filter flare-up procedure to the services offered by the Cigarette Testing Services Division (CTSD) Status: Personnel of the CTSD have been trained and are running the filter flare-up method. Any requests for this service can now be directed to this division. A smaller design of a high volume smoking machine is being built by R & D Engineering for this purpose. C. Philip Morris Standards Laboratory (B. Mait, R. Wiley) Objective: To standardize the analytical testing procedures in all Philip Morris U.S.A. and Philip Morris International Laboratories. Status: Standards for RTD ventilation, and circumference are now rotated on a bi-monthly basis to eight Philip Morris domestic Q.A. and R & D laboratories. Results are compiled and a report is issued at the completion of each rotation cycle. D. United States Testing Company In cooperation with United States Testing Company and Philip Morris International, a survey of cigarette brands on the Brazilian market was conducted. The purpose of this survey was to provide advertising claims for Philip Morris' Galaxy cigarettes on the Brazilian market. In Brazil, Galaxy is advertised as having the lowest nicotine delivery of any cigarette on the market. IV. Presentations, Reports, and Memos A. G. V. Carter, "Water Precision Study," Special Report, Accession No. 84-206. B. R. W. Kanipe, "An Automated Gas Chromatographic Determination of Menthol in Cigarette Packaging Material," Special Report, Accession No. 84-111. C. C. F. Dawson, "An Evaluation of Filter Efficiency by Automated Photometry," Special Report, Accession No. 84-200. D. C. C. Bright, "Survey of Nitrate Nitrogen in Cigarette Filler for 1983," Special Report, Accession No. 84-133. JFS:rad