PRODUCf TESTING AND PRODUCT OEYElOPMENT BEST PRAC"TICES Contributions by: Brlt~sh-~Parlean Tobacco eormpany, eiOarottan-Fabril(on Brltl~h-Amarl#n Tobacco company, Limited Brown I nllti~mson Tobacco eorpontlon ComptnW1 Souta Crur Industrfa E Camerelo Iqeriat Tobacco Products, lmltel APRIL, 1992 copy: ~ LIMITED: 00 NOT COPY OR SHOU TO ONAUTHORIfEO PERSONSI Clit; PDF -!::!!::!!::!.f3 StlC.i: 0111 PRODUCT TESTING AND PRODUCT DEVELOPMENT BEST PRACTICES TABLE OF CONTENTS Paae.lloL FORE~OAD ~ ~1~I~~~~~~~~~.~~·~~~·~~~··~~ 2 1, PRODUCT RESEARCHITESTING ' FOREWORD, 3 PHILOSOPHY AND BEST PRACTICES , 4 CONSUMER NEEDSIBEHAVIOR TRACKING I . 4 EXPERT SMOKING PANEL 4 CONSUMER PRODUCT SCREENING 5 FULL-SCALE CONSUMER PRODUCT TEST (CPT), 5 CONTEXT ASSESSMENT 6 AWARENESS, USAGE, AND CONVERSION TRACKING , 6 ON·GOING PRODUCTION 7 ON-GOING CRI'IIPUE AND ADJUSTMENT 1 8 COMPETITIVE TESTING PRACTICES 8 2, OVERALL PRODUCT DEVELOPMENT PROCESS ESTABLISHING GOALS AND OBJECTIVES 1 10 PROJECT ORGANItAfIONAL STRUCTURE 11 PROJECT PLANNING AND EXECUTION 14 PROOUCTION/U)MMER[IALIU\IION OF FINAL PROTOTYPE . 21 3, CRITICAL USIB PRIMARY PROCESS OPERATIONS FOREWORD , 23 PROCESS I I , , , , 23 4, PRODUCT FORMULATION OVERVIEW 27 LEAF BLEND 1 27 BY-PRODUCTS , 33 CASING ANO FLAVORING 42 CIGARETTE DESIGN 1 1 47 5, APPENDIX APPENDIX 1, SOUZA CRUZ PRODUCT BRIEF APPENDIX 2. GENERAL GLT ANO PRIMARY PROCESS Clit; PDF -!::!!::!!::!.f3 StlC.i: 0111 FOREWPBD One of the major challenges facing BAT is to consistently deliver products which are judged by the consumers In ed market to be superior to competitive offerings. Successfully meeting this challenge repulres the effective application of innovative scientific capabilities to Improve product performance, Management of the process by which this occurs - product testing and development - Ire critical to the ultimate success of thess efforts. Project management teats and techniques are essential in directing the product development proeers~ Effective project rmnagement ~llows the balancing of the potential benefits of pursuing pronsing technologies with the overall project objectives, cost, ad schedule, Also critically Important is the consistent use of reliable, effective product development practices regarding the identification and evaluation of new technologies and designs. This Handbook sur~narizes the best product testing and development practices currently utilfled In BAT, it has been prepared by the 8~ and BATCF staff with significant collaboration with BATCO, Souza Cruz, llmasco, and BAT Suisse, While the emphasis Is on US1B, the testing and development process described here has equal application for all BAT products~ The scope encompasses all phases of product design and testing from the establishment of initial product objectives through final consumer testlng~ Every product component is addressed in this framework · led blends, casings and flavors, reconstituted tobacco, ROOT Technology, non·tob~ceo components, and cigarette design, -1- Clil; PDF -!::!!::!!::!.f3 StlC.i: 0111 OVLRYIM The taste characteristics of leading international cigarette brands an becoming increasingly uniform throughout the world, Changes which took twenty years in western Europe are already occurring in Latin America at an accelerated pace, Product Oevelopnent BEST Practices recognize this and lead nther than resist change. BESI Practices accept as much stmdardintion of materials Is possible and Ire based on agreed measurement standards, BEST Practices strive for simplicity whether It be In characteritation of leaf grades or formulation of flavors, BEST practices avoid "munba-ju~mo" and 'not Invented here. BEST practices are factual, obSeetlve and receptive, BEST Product Development Practices follow Total Quality principles, Our Mission is Superior Customer Satisfaction: I For product development, this means products preferred at the 95X confidence level In sequential Ponadic testing plus supporting attributes among target (200·400) consumers, We work as a Team: I With Marketing and Marketing Research in developing the Product Brief. ~ With Manufacturing and Engineering in developing the product designs and technology transfer. I With the combined expertise of the BAT Group for enhancing smoking quality and technical interehange~ We do the Right Things Right: By rigorous up·front project planningl t By developing sud testing hyeotheser far product Improvement~ ( By ensuring that 111 materials and designs are In compliance with current and anticipated regulations, We Provide Products and Services of the Highest quality: ~ By continuously increasing our scientific underpinnings of tobaccolrmokelJensory chemistry, and especially our understanding of Root technologies, and By using robust assign principles which allow for variations Introduced by our raw materials, suppliers, or process capabilities, ·2· Clit; PDF -!::!!::!!::!.f3 StlC.i: 0111 "~:= ~ ·,c.~·-*· L·l ··' rl~C ·f:f.f ~LI~U*~::~J~I~(·~(~~r~~ -1~ I ·~~~~ " "'~*~ ~··:· I:·· '· ··:~ " : ;'~ · .I.r*.*S ·. .·:I (·I *·yl::·i:l ~~ :I :... :·'?1.. ··~·:~··1: :·::~ · ,·;··:. ~:·· ·· FI "~f. .i ;·:fr: ·~;·:t·a ·~· :~5~.-l·iiitll: I(Y*·· ,. .: . i ·:·~5~ .···~· .·.-.: i .· L .I* . .t; I·I .rcv·,~a.s~r;·;~·i;,·r Tli: "- Stl ,;ji ·?*~ :::; rasl C ~- ~5~ .,.....;1t· -· · '' ·~· ,, ·C L1 .1- I·c~ 't"~i ;~· ....· ···· - ·.· · -·~:· '~" h ·~jc*i~lf=l·:lw~~;~cF_t~itru~Jt~R~r~&L;n~f,?~'~.~M~II~BIAt~BI~?~LI~·F~\;;(5?~~! ·'·· :~·~'~· I :" :··i'~"' ·' '"" *' ,Z I·i: ·:·i L; ·- :~ l~y~E;45r .~c~'-;6J;lt·~~·~:;~;' ~· ·~ *V·~ ~I'·~' i; ~'C~ I ~ :*. ?! r~* ;'"'' (i17 :;i:·,C '' c:··. :I~n:~n::yyl ~C e:;I,~Nt " 'r% ·:r: ~i ~ a*,'~ ····-·· ··· · lr· :~:!;·r·c~ :~L~ 1··1·1 ~n~5~.~* ~"' ~i~~i iR ·) ~"n~j ~;· ~" ·:~ ~u~- ··.; ~ ".·"·"=I~: :C ·. i,: ·- ...; s!~'2?2'~;.iQ) ;" :::·· '·r· ··rr. '* d ~''' :~;B~ ~· ·*'*"'~r. ,Ei "' II ~: BLE:Y;~;~.~~~_;"~;·XMUCRj~]UII~F~I~RYJ~Rp'P·mL~il*a;Y'W1Ur~DIII*I1*WFI~1.*P~~I·tl(i;:. ~ ·1 31~:: .~i O .. .. ·. ~I r0· :· ·;r· ,, ,,ap -I"·!·;: ··-;- i,~ rl· ····l.:r~~~· ~~.r::, " O :: ! P-gi: r· ··-s.·,:···,l· ;" U1~ : · :.. ::: b ··II :IZ.B*'*" t'ic ·: a- ·· ·i· · .*~ O ::. .. ,, ~r:;'··r·. ... ·· -··· 1. ·, ·-···. r:·:h: ~·····l';~,~:y!,· : ·~ ·· X. .:;· ic~ '.r. ..i~. C: I i I; PDF -!::!!::!!::!.f3 StlC.i: 0111 i. PRODUCT RESEAREHI'IES~ING FOREWORD Throughout the product development cycle, eonsu~r checkpoints Ire required to assure on·going linkage with consumer expectations and perceptions. This consumer feedback is needed to fat appropriate initial direction far product development, to provide guidance for mid·courso corrections, to assess progress, to recognfre success, and to monitor on-going mlrketptaee performance. The following diagram represents I model of progressive steps and attendant research In the product development process, PRODUCT DNE1OPMENT PROCESS ~i· ~sacssuDn wldlm a opmRunen rnarorm 'WIL~EMu~lG casw wr ~R~oueM1as4Mwa OFN89S rROWC1 S~MM 8888 DSpn~HB O nlotKo~plgl #YISUIHEEDSI RILLBeKB PMUIPm BDUVKIRTR~C;WIO WW(W C~IUGI #W(GUYER WWGE~HD 8888( BCRED~NO WXIIIF1~EGI #mwmKH ~R~CKD~ eDP~SUMEREHgaBOINTB ·3· Clit; PDF -!::!!::!!::!.f3 StlC.i: 0111 r PHILOSPPHr ANII.BEST PRACTICES A description of the purpose for each phne of resting, LpPlopTilte methodologies, ed governing principles is provided for each of the consumer research checkpoints: A~ eONSUnER NELDSIB~YIOR TR9CK1Ne Phllorcp$: A conprehenrive, on·gaing monitor is needed to keep up with changing tastes, perceptions, and leeding indicators of consumer preferences. Data coIlected at this stage of research serves Is a stimulus to concept development for new products or product tnnontion~, Best practices: Reprerentdive tracking studier should be used to monitor smoking incidence and consumption (sticks per day), consumer awareness, trial, and usager product and user image perceptions; brand positionings; and brand switching infonnation by sociodemographie group. Research cycler should be sufficiently frequent to detect emerging consumer trends and need~lwants on 1 timely basl~, pelevant user subgroups should be lepantely Identified and analyzed for behavior and attitude differences. information should be projectable to the total smoker population. B, EXPERT SnOKER PANEL Philosophy: An elementary testing technique is needed to screen unacceptable products from large numbers of sample candidates produced in product development or leaf blending work. As an early phase of testing, therefore, this methodology should require linimll material usage for IppliclttPn in situations when only limited hind-lade product samples are available for evaluation, The result of this stage of testing should be idmtifieltion of the range of magnitude of basic sensory attributer, detection of the degree of differences between products, and elimination of those candidates which clearly do not meet the product brief, Best Pnetlees: All companies in the group use in·house panels in the early stages of product development. There generally consist of the project staff with their own expert language, but may be supplemented by tnined employee panels if necessary, .q. C Clit; PDF -!::!!::!!::!.f3 StlC.i: Dill t, eDISVMER PROOU~ICREEIIHf philosophr: This is not mandatory but may he needed to determine the effect of product modifications or innovations among consumers, and to identify leading candidates among test Product vlriltions~ intensity of various product attributes is of major concern in this phase of testing, to prnvide product developers guidance in understanding how various product modifications translate to the consumer's smoking experience, Best practices: A good intermediate screening procedure: · Allows evaluation of limited or pilot plant samples, Is cost effective, · provides fast turn·lround In the product development cycle. Relieves the smoking load an internal panels, · Is nominally representative of the target consumers. Ideally has predictive capability for attributes if not for preference, o. RIL·SCIIE caNsunER PPOUeTDa re~ Phll~~: This test is the singh most important In the continuum of product testing, Is the final arbiter of consumer judgments, elven the impact of product decisions on potential marketplace performance, the sample sire for this test should be sufficient for good measurement It the 95X confidence level, Minimum sample cells of 400 are rceb~cnded, Smaller samples and lover confidence limits will invite "pzrity" results and erroneously lead to assuming product competitiveness that doll not exist~ This could lead to disastrous results in the marketplace, Sequential monadic tilting should be used to assure consumers evaluate products without the confusion that results from paired compari sons, Monadlc results Ire not recommended since the sample composition II different for each Fell, Sequential monadic assures a perfect match since the same smokers try both products, sufllctent qu~ntittes of cigarettes should be smoked to appraxlmlte the ro~l·lifo smoking experience as closely as possible and allow for ~cclfmatlon to the test cigarette's smoke chirleterl~tiel. In·home rather than lahoratory testing should be used so:hat consumers smoke in accordance with their normal practices (time of day, cigarettes per day, visual situltlans, familiar surroundingslltlmull), Blind testing should be used to eliminate visual bias, and to prevent brand inagelpackaging from affecting test results. -5· ClibPDF - v~~fastio.soni 1 _ Best practices: In-home sequential nnldic testing should be conducted with two to four hundred smokers for key product decision making, Best practices use coding to avoid or neutralire number bias and take special care to match age with competitive product. Sample production should minlmite variability, and preferably be conducted In the factory, E, corrracr ~nssEssaEtrr PhlloSpphy: Since products will be marketed In the context of packaging, promotion, and advertising, an assessment of the ~a:~jbiilty IcPnanincl i of these elements is needed prior to test Best practices: pualitative Total Offer Tests provide 1 valuable cheek of the consonance of all elements of the product offerings Both one·on-one individual interviews md focus groups may be used to explore consumer reactions to packaging, advertising, promotion, and product, and to probe underlying feelings and rationale, One-on·one interviews often reveal personal feelings not expressed in focus groups, while group interviews reveal social IntenetfonJI behaviors not apparent in Individual sessions, If doubts exist about the qualitative results, these can be confirmed In a quantitative in-home placement TOT, but should not be expected to provide reliable projectability to predict national results. Same BATCO companies cannot perform Qualitative Total Offer Tests with the rigor of the CAC companies. In these situations a. pumtftative Total Offer Test, under refinement by BATCO, may be lore appropri ate, pualitative and puantitative TOT's are not mutually exclusive, Both may be appropriate but not in all circumstances, BATCO requires a quantitative TOT as polity in International Brand applications due to need for representative sampling and to adequately model brand image positioning, effect ofbnndfng on product sensory perceptions, and Id responselprfce sensitivity, Sufficient consumers (100f) must be used to ensure consonance of all elements of the product offering. Whether the methodology is qualitative, quantitative, or both, it must have the rigor to uncover any changes needed before test market, F, BII~RMESS,IISI\CE, AND COHVERSIPN TRACKIE PhllPSPDhY: New product introductions or blend changes for current brands involve considerable financial risk at the national level, lest markets of sufficient site to be projectable should therefore be employed to assess product land program) acceptability in live marketplace litultions~ -6· Clit; PDF -!::!!::!!::!.f3 StlC.i: 0111 The result of this Stage of testing should be assessment of product acceptability among consuaers bared on product as well as advertising pwklging, and promotion characteristics (cPnversion rate, loyaltr awareness, trial, 1Plge Best practices: A rest market is the final step of the product development process and is agreed by all conpanles to be an integral part of Best Practices product terting~ Given the financial maonitude of launch decisions, test markets are considered mandatory unless impossible due to a specific market condition, Test markets typically run for a minimum of six months or more, Ouration is largely affected by teal conditions and the time taken to red steady field conditions. Best practices include .1 c#rbination of data which includes rhlpment, retail off·tlke, and attitude and usage surveys. While the frequency of these varies to some extent, shtpnent and off-take data is normally examined on a weekly basis, with less frequent measures of awareness and usage data, Additional supplementary data copes from consumer conwents, and sales force reports which can describe important competitive Kt~vitler, 6, ON-GOING PROOUeTrPN PMlosaPhY: On-going assessment of product performance versus competition is needed to trigger Improveeent work, detect changing consumer tastes or competitive product modifications, and let priorities for future development work, lhe importance of conclusive, projectable results from this phase of testing is equal to the full-scale Consumer Product lest, fhir testing phase should therefore employ an identical sethPdoiogy. Additionally, It is Important to provide the consumer an opportunity to express views about product performance It his option, not jurt when recruited for research studies. Best practices: tPI Honltors: identical to full-scale tonsuser Product lest, Consumer Conrments: Toll-free telephone numbers may be printed on all product packages to encourage direct contact with the manuRetufer, Consumer comments received daily serve as an early warning system to detect manufacturing problems, and provide valuable feedback about product quality, -7· Clit; PDF -!::!!::!!::!.f3 StlC.i: 0111 I, II·PIIP PIT~PIUD 1IJl~~lnmm almES) As the clntrll product measures In 111 phases of development testing, 'product Itt~~tlr" tuft be ElrefullY selected Id plrldlCllly re-examined to assure they satisfy vital performance criteria, Effle~vs utillrltlen of Ittrlhtes repulrer they be nlnlgd It two levels or research, It first explores needs and perceptions derived from consumer txpeetltlons, in these early detection' phases of consumer monitoring, attributes must be sufficiently sensitive, descriptive, flexible, and complete to clearly articulate consumer direction for product development, ( The second deals with practical assessments, where products are consumed and evaluated based 01 various smoking chlnctlrlltfel. Both levels demand the careful selection, application, and understanding of attributes to assure they remain relevant and capable of providing needed direction for product development from conceptual st~rt·up to final delivery, Focus groups are the best source to determine the attribute set, ~a be nort effactfve Ittrlbutes JhDuld ya~le~s the hllowfng ch~r~ctlrlJtfcs: IELBCE · Surveyed attributes Ibould be those factors which influence smokers' bond choices. ~~SeRInI~rON - Attributes should 'sort" brands Into distinct groups. ~~EIM~B~ - SIPIFdl attributer ShOUld net be ltrengly correlated to each other, · eulm · Attributes sCould be comaunicated consumer tent so that it Is easy for ordinary smokers to understand, · CphplETUlFSS - All important dimensions of smoker brlsd·clolea should he measured, while different retr af Ittrlbutes mey be eperepFiete for valeur stages of tasting, it is essential that they be compatible, and that they be uniformly defined and dllal stered throughout the research process, I, eBI~ITrlE ~~I1S ~TItE~ ehilip Hc~ls end b J, Reynoldr use mail olnelr fn the UJ, for much of their product tilting. Ihe attribute sets contained In the puestionnalres in similar to those used by B~, Yhlle mail panels in potentially cheaper in-home placement and interview provide better qu~fty contrel ;f thfs key terting process, ·I- ClibPDF - v~~fastio.soni 3 LI X:KIO 3 cI r ·r 3 > r w 8. 3 3 3 I I 3 1· K KnIIK a pt PI e c +I c r e ~-· Y *I PI u B E * 3 1 3 3 O 3 3 F r rr g; w w * * tx~ u u u m s E E PI 3 c PI L O PI I inL L Y 5 uUA U U u V]# ~n c ~ 'p~ w OIU O O 1 IY KC~r*l LPI)~~~ W IY I 3 " PI tVI r r u ,aP LUAOL, IOD h013WI 5 E' 5" t ci I r L a ~lr~r 01 OC sU n r E J *I Y yr cin E n E " CY) EO O B u ru wv O 3 V) h) a r53 N a I;: u Clit; PDF -!::!!::!!::!.f3 StlC.i: 0111 3 3 I') 1 3 s 3 o .r h) P3 ;3 oN IS~ Er Q1 Clit; PDF -!::!!::!!::!.f3 StlC.i: 0111 2, OVERALL PRODUCT DEVELOPMENT PROCESS Successful product development is contingent upon not only following prescribed best practices for the developlent of the final product, but also on an overall process flow which optimizes technical integration, coarnuniation and deeision·making~ In order to maximize the probability of meeting both the performance and timing objectives for a product deuelopment project, the following elenentr and process should be 1 ncorporated: ( Establishing Goals and Objectives, I Establishlng/Flnallzfng Organizational Structure, ~ Developing or Adapting 1 Project Plan. I eonmunicatlng the Project Plan, ( Executing the Project Plan, I Ptoduction/Co~nraerc1atlt~tion of Final Prototype, Both Rarket·driven and technology·driven projects follow this general now, Where differences between these two types of projects exist the differences nill be mentioned, ESTABLISHING MA1S ANO OBtRIVES The first step for all product development projects must be to establish and incorporate clear, well-defined objectives in awrltten Product Charter or Marketing Brief, Objectives for the product characteristics must be based on sound, relevant criteria, ad to the extent that these may not be known, research Ily be required before flnll objectives can be determined. The charter should contain definitive performance standards against which the project outcome will be measured. At 1 minimum, it should contain: 1 Smoke pality objectives including the sensory testing methodology to be used and the criteria for success, target or benchmark product(s) and target stoker group(s) · Product phyrical/cheai;al characteristics such as dineaion~, delivery ranges or limits, physical quality expectations, etc~ · Constraints, limitations. · Timing · project completion date, critical milestone ddes~ The Product Uhrter or Marketing Brief is very important, Sales trends and switching studies provide the market dynamics, These in turn se partially explained by both attitudinal research and actual sensory experience, In the "Best Practlees In Product Testing" Conference held In January 1992, the CAC delegates described the Ideal brief as follows: ,Dercrlbes how the product fits into the overall marketing strategy, I Shows key points of the analysis supporting the brief, ( Defines the target consumers, I Give, physical definition to the cigarette and packaging. I Provides action standards for formal consumer testing, I Contains guidelines on sensory smoke character, e Gives test market timing, ·10· Clit; PDF -!::!!::!!::!.f3 StlC.i: Dill While the format of the brief will vary from company to company, that used by Souza Crut is given as an example in Appendix i, The determination of goals and objectives for marketing-driven projects is the responsibility of the Marketing department, but is done in close conjunction with RaD, For teehnologyarfven projects, the initial goals are determined by the technical functions, such as RSO or Engineering, Other departments such as Manufacturing, Engineering, Purchasing, etc., should also be Involved In the objective setting phase as appropriate for the scope of the project and the project objectives. The step which finalizes the charter serves as a feasibility check, and Is a joint process between Marketing, Marketing Research and RLO for both market and technology-driven projects~ The feasibility check must also include an assessment of the tools (e,g,, materials, processesltechnol ogies, etc,) needed. For projects with shorter timetables, where resources Ire Ilmited, or which are expected to be rapidly commercialized, only those tools which bye been qallfled as proven positive contributors and ready for use (mature) should be considered for the project, For projects of longer duration and where resources are available, tools which have not yet been fully developed and qualified can be incorporated into the project provided adequate steps to assure commercial viability are taken, The Product Charter must receive Senior Management approval before proceeding to the planning and execution phase of the project. ppOjECT ORGANIZAT~ONAI STRUCTURE An appropriate organizational structure for the project must either already exist or be established prior to planning and execution of the project, To be effective, the organizational structure must establish a clear accountability for the overall management of the project, provide a sufficient infrastructure to maximize the project scope and integration of development activities, and provide sufficient senior level support for decision-making and issue resolution, The underlying principle for the project organltation should be to keep the information flow as short as possible to avoid loss and/or deviations from the project's initial Intent, The same principle applies for the decision-making process. The elements of a basic general organizational structure are shown below. Because different organizations vary in size, numbers of people in various product development technical disciplines, and management structures, a single organi~ationll structure for product development cannot be defined, However, the elements shown below represent those needed in some form to ensure the accountability, integration, communication and decision-making criteria outlined above, SteerlnP eo~lttea or Epufvalent in some organizations, 1 Steering or equivalent committee which oversees all product development projects may already exist. In orglnftltlonr where It does not, the formation of i Steering Qrmnittee for a specific project Is required when the project Is very broad in scope, his large, multi-disciplinary resource and operational requirements, and impacts directly the strategic operations of the Company, -11- Clil; PDF -!::!!::!!::!.f3 StlC.i: Dill The Steering Connittee should be composed of senior level magelent representing the principle areas involved in product development projects. ~he function of 1 Steering Eomnittee is rot I Ensure that the strategic approach of the project is congruent with Corporate strategies and objectives, (APP'"" or ratify the Project Team's reconnendatlons. · provide hlgh·level support, through dedrfonrking Dr resolution of priorities/issues which are beyond the scape of the Project Team's or Project Leader' r authority, 'Comnlunication across functional areas, Profectleadar The Project Leader is the Individual with overall accountability for the project, functions of the Project Leader include: I Establishing objeetf ver withi n components of the project consistent with the overall project objective, I obtaining/allocating both the Ipaopnuer and financial resources necessary for the project, 1 Defining PFioritieslrerolvlng priority conflicts, I Faflllt~tin9 declsion·laking, ,Assessing and monitoring project progress versus objectives. ( Comn~unicationlreporting · both to the Project Tea and the Steering Comnittee, Is well a to other key operational functions, Ideally the Project Leader Is 1 member of the Steering Committee, and in t~hEl::,Or'ajol Ilrket·d~iv~n projects also 1 n;ember of the ml~hting erdeet.~p~. taam lhe functions of the Project Core Team include: · coordination of project activities Including monitoring the progress of the individual elements of the program and making adjustments when necessary, ,Day·tP-d~y decl~lonakinp ineludfng renentnglfnterpretlng experimental results followed by establishment of next steps. I tntegntion of findings from the individual project areas into 1 final development phase, ( Con~Runiation of project status and Issues to the Project Leader. · Core Team me~a~ers may also have specific task assignments in addition to coordination responsibilities, Depending MI the scope of the project, the Core Teen may be colnposed of individuals doing the actual development work andjor individuals who bye demonstrable project management abilities in the areas that the project will encompass, For small projects, or for organ~t~tlons with a small product development grasp. the Core Team will be made up of the ·12· Clit; PDF -!::!!::!!::!.f3 StlC.i: 0111 !pectllirtr (see below) doing the actual development work itself, Tn larger organizations, when the project is large In scope and requires moderate or large nualbers of resources (especillly multi-disciplinary or cross-functional resources), the Core Team functions more as a coordinating body, but should still be composed of Individuals who possess a high degree of expertise In the key development areas of the specific project, Core lean members may well themselves direct the activities of Core Groups Involved in major tasks such as Processing, Packaging or Tobacco Blending, Soeciatists Product development is a e~eative, highly interactive, Integrated yet ~oriented process of blend, carlnglftavor and design specialist The pusIlflcatfons of the speei~lf~t~ chosen for the project Is a key factor for the project's suecess~ The fundamental puallflcations needed are: ~ Excellent sensorial abilities and the ability to cornnunicate the subjective impressions, In·depth knowledge of the sensory effects, physical effects and Interactions of materials and processes employed, I Comprehensive knowledge of the factors which drive consumer preferences, I Knowledge of ether relevant product characteristics, their importance, how they interact and how they can be influenced (deliverieJ, costs, availability of materials), · Ability and willingness to work as an integrated team, I Creativity, intuition, imagination, project Plannlns nanarrer For large projects as described previously, and far projects where extensive, detailed plans are necessary, the formulation and tracking of the plan is best handled through the use of a Project Planning Manager with the assistance of computerized project management tools, The Project Planning Manager should be part of the Project Core Team, and should have experience in the use of project management techntques, concepts and tool s, The responsibilities of the Plannf ng Manager Ire to: I Coordinate the development of the initial plan, I Track and communicate plan status and progress, I Communicate critical areas of concern to the Project leader and appropriate Task Leaders, · Examine new tasks and determine their impact on the project schedule, ~ Examine options to resolve schedule delays and conflicts, and make recomnenditlons to the Project leader, Computerized project planning software is simply a tool used to simplify the complex task of plmlging project tasks and resources, Thus, It allows the Project leader and Core Team to optlmite~the project flow and the utilization of resources, and to develop realistic project schedules Including schedule nodifieation when changes occur during the project, For large projects, this cannot be done manually, · 13 · Clit; PDF -!::!!::!!::!.f3 StlC.i: 0111 PROJECT PLbHING bNO EXEE1TlON The next step following the agreement of objectives and organitatlonal structure is the developrnt or fislization of the project plan for the project under consideration. Project work should not be initiated until the Initial project plan II completed and approved. The overall project flow and the pian detail wpuired Ire 1 function of the scope of the project and dependent on a number of factors: the difficulty of the objective, the number and types of specialist resources Involved, the extent to which current pllterills and technologies suffice to reach the objective, ed the project duratfon, The I types of projects which lend thenselvel to different planning processes Ire described below. PFakee~ Repulrln~menl plans Prajortr rhid Ire nodes; In scope relatively short in duration, and which are achievable utilizing exlrting ;aterillr and processes do not repulre extensive or detailed project phnnlng~ There are also projects derived from market requirements/demands (e~9·) activities of competition, changes in brand switching, legal repu~reaent~ like introductions of tar ceilings, etc.) which have a short time horizon and a defined end-point (the date of Iluneh)~ The launch date has 1 very high priority, and in some eases (e.g., tar ceiling Ilmg from January 1, 1993 In the fC) the modified product has to be introduced even if the product has not fully reached the taste qulilty target A 9eneralized project plan and flow for such types of projects should ideally exist in a wri tten format In all CAC companies which giver I broad dererlption of the important steps along the time ale of the project. The central product development portion Is executed in a variable number of loops until the objective is achieved. Filming for there typer of projects incorporates: OetennininS critical milestone dates (e.g,, interim results, date required for final prototype selection, dates required for tPT nultr In order to meet overall project completion date), ( Determining the number of prototype development 'cycles" possible within the framework of the milestone dates. I Oevelop~ent of a broad product 'concept" (see below), ,Oetenining, in broad terms, the best product development route. The mutual development of a broad product 'Eoncept' includes the Following: I Mutual sensory evaluation of the target product(s)~ I Review of current status with regard to sensory, analytical and other relevant information (nost successful produettlePmpany), analysis of strengths and weaknesses from the consumer's viewpoint, ( Onninq eoneluJibns about the functions of key product features of the target product(s), I Review of existing tools (knowledge, materials technologies), I Oetereining, if necessary, input from internal and/or external sources. ·14· Clit; PDF -!::!!::!!::!.f3 StlC.i: Dill C _ A diagram of the general pmduct development flow for this type of project It attached (tlgure 1)~ key to the successful execution of the plan is: ~ Continuous connunlation between ~peelllitts about effects, contributions end Intanctlon of individual toots and materials towards achieving the sensory obje~lveJ v Hutal sensory avalubion of 111 development samples, comparisons to target produet(s), and selection of candidates far consumer product testing ( nutual review and laesslwnt of achieved intermediate results (analytlcall em) to determine next steps .15. Clit; PDF -!::!!::!!::!.f3 StlC.i: 0111 Figure t Dsllol fhlror Inolutlill rclllo~llly G~~~k Alllllnlnl or tlpl ~roaull 'Illnl Ixnlrll 1I1 Lr(,~ Colun 'Cllll(l~llror el(lrl I~nnPhll Wonl(nol(oo 'Oll((lll)lr(l III11 IIDorlo Ononlnn )nlucl 'ePnlool' , Ellln~l~l~r~r Ll)lrln Dlloull I I(r,~ On Ollllno ,DnISn Ol(nrlo (Ilonl I~llr~l) (ellln( I~~,rtll (Dl,lln Iloorlll dn~~l Ilnnl, ellou. 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N C rC O L: L': Clit; PDF -!::!!::!!::!.f3 StlC.i: 0111 ~ __ Prgiee~sRePuirlnp Detailed Pt ans for larger projects which likely require the development of new materials or processes, a generallled plan might not be sufficient. Typical projects of this type emerge from: ( The identification of a deficit In the product development "too~·bax" For achieving certain product attributes with existing or slightly modified a~~terials/technologies, The target is to develop new innovative stools" which may be necessary to overcome or eliminate the deficit and provide a better than·tarqet product taste. · Innovative ideas or concepts, The target is to convey the idea that the function of the Innovation gives the consumer an extn "preemptive' benefit (unipuenesr, competitive edge), There tYPes of projects diifer from naket·driven projects with regard to the following aspects: ( They are more performance the schedule oriented, · They are broader in scope and require the involvement of more technical disciplines (e,g,, applied and fundamental research, external consultants, engineering, machine manufacturers etc.) additionally to product development specialists, · The result is either a new material/process or innovative product which has been proven for achieving the wanted product attributes in thoroughly planned analyses including CPT. From the end·paint of these projects there are two ways to proceed. In the ease of new materials or technologies, they become aaitlhle tools for the product development specialists, In the case of innovative products, the development of the marketing concept (advertfrenent, pack design, etc,) has started early enough in time for Iwnching the product when all technical requirements for full·scale production are fulfilled. petalled upfront planning Is more essential for there types of projects because It: I Provides the basis far optimizing and balancing the eostlschedulelperfonnance elements of the project, Provf des real Istic expected project completion dates based on a known program of activities. I Haximizes utilization of resources by early identification of what resources will be needed and when they will be needed, thus reducing the risk of conflicts, duplication of effort and missed schedules. I Identifies critical path development flows, I Maximizes Input, participation and comnitnnent to reaching ob5ect1ves. · Establisher clear and mutually agreed upon responsibilities and accountabilities prior to the initiation of the project, An example of In effective project planning flow is attached (Figure 2), Step 1 in the flow establishes the fundamental approach to the project, and determines whether the flow will be sequential, parallel or a combination of the two. -11- Clil; PDF -!::!!::!!::!.f3 StlC.i: Dill Figure 2 j ROIPC1 Pl~nn n~ R~w j Project Planning F16w Pleliminarv Plao aeveloame~n~t Develop and approve overall project flow and milestone dates, 2, Gather Input from speciallstl on areas for investigation (brainstorming), 3, Assign task leaders responsible for sptteific areas for Investl~aticn, i. Have task leaders develop detailed plans within each area of investigation. 5. Priorltite tasks within saoh area. 6, Integrate detailed plane from each area into a total preliminary plan, Final Plan Deuelaameaf f, Balance nloureea within on area, 8, Prioritite tasks between areas, 9, Balance total project resources, 10, Rationalize tasks to achieve completion date, Review schedule accuracy with task leaders. 12, Obtain approval of final plan, 13, Communicate approved plan and Initiate activities. ·18· Clit; PDF -!::!!::!!::!.f3 StlC.i: 0111 Projects with 1 total emphasis on performance criteria are best served by 1 sequential development flow, In a Sequential project flow, development of 'key' or most influential elements Is done first to ensure they Ire aptimired, This development is followed by 1 progressive, stepwise Integration of less influential or less critical elements on top of the previous base, The sequence of development Is project specific depending on the target product and the smoke quality and physical gulllty objectives, The major advantage of a sequential flow Is that the most critical elements of the final product Ire developed early in the process, and that subsequent development can be tailored to the previously optimized base, The major disadvantage Is that sequenttal development an significantly extend 1 project's completion time, Projects which are totally schedule driven are best served by 1 parallel (s~mult~neous) development flow, In parallel development flow, the individual elements of the final product are developed simultaneously, then integrated In more or more eombining phases into the final prototypes or end product, The advantage of parallel development Is the shortened development time, Disadvantages are more conflicts for copon resources, and the recognition that elements optimized independently may not result in In ~ptimited final product due to interactions and synergistic effects during combining, By necessity, most large product development projects are driven by both performance ad schedule criteria. Therefore, most project flows have both parallel and sequential elements - work in the individual development areas is Initiated In parallel, but emphasis is given to the most critical factors or to long leld·time developments early on, ad the combining phases are somewhat staggered in a sequential fashion As In the case for the generalized project flow, integration of the expertslspeciallsts and task leaders across the development areas is necessary due to interactions of the individual elements of a product, Independent developlent of components without this integration are unlikely to result in a optilited product when combined, Paints in the process where this integration can occur are in the preliminary brainstorming, Task leader meetings to review results and eltablish next steps, and in group sensory assessments of prototypes, A diagram for the overall product development proton for tHs type of project is attached (Ffgure 3), The actual product development execution generally proceeds along the following flow: Bench/pilot prototype production and screening for each of the genenl product elements (e,g,, blend, recon, casings, etc,), Review and dedsions regarding next steps se made by the specialists and Task leader within that specific development area, ( Prototype production and screening of the lost promising candidates within each ln~ Revfen and decllion·~aking regarding next steps is done by the specialists and Task Leader in the specific development eel In conjunction with the Project Core Team, -19· Clit; PDF -!::!!::!!::!.f3 StlC.i: Dill Figure 3 Overall Product Develooment Process t RID-Orl~o I#lor Rrol(oI rnllmlney Charter --cl Umlg,m,n~ Prglnlulloall rrol#1 ApprOvll Blruelun (Mlrk,lln~ I rroj(ct ~~~dlr I Mlnul~oturlng 'eor~ Llla ,Englol,rlo~ '81~1rln0 Comnlttl, 'Olh,rl ~0111# Acoount~bllltlll Foliow~., Se~u~nttal Flow ' I,,,.,,,, I Illllll r I·II·# C~n;ll 11111) 11111 ( ert Clnll~lll rllr~r D#lln b(lln( 01,, Paralld F~w I~COn cj CIIL.(II.*IDII111 OltlJbd )Iln e'' O'"""''' Cltlnl 18Fh~dul, ( A#cll I Rlvlls ~i O ~-8 8lnlor Inllllll )nllnln~ry Mlwp,ll~nt APPrOVII rroco~ypll RtOlP1YPII Al~#l I R,vln 8-8 B ~i Stnlor ~UIIIPII( Ap~rov~ Mlnlpcm,nt +I- Conlum,r rlnll Ap~rcvll k~linp Clndld~Ul ~ Al~c~ll Rlvi,w I Al~~~l I Rtvllw ·20· Clit; PDF -!::!!::!!::!.f3 StlC.i: 0111 I" I Production and screening of eonblnations of the aost promising individual elements. Review and decirion·luklng regarding next steps is done by the lask Leaders, Project Core Team ad Project leader, In specific instances, approval to proceed with components with high financial or operational impacts may require input from the Steering Coanittee~ ~ Production and screening of finl) prototypes and determination of candidates for full·rclle sensory testing. Review and reconwndatlon is done by the Project Core Tear and Project leader, with ratification by the Steering ton~lttee, Rewfre~nents for Bath tvwr of Irolects Regardless of the planning process or execution flow chosen, 111 product development projects regnre reviews at various stages of the process (fndicated on the diagrams) to: ~ Establish adherence to br devlltlons from established criteria In the areas of sensory results mllytte~l parameters or limits, previously established constraints (costl tianing), ( Review results and Issues from seate·up trials. I Set material standards, preliminary product standards and measures for quality assurance. ( Set component list/data plan~ ( Establish introduction volume Including approval of material purchaser. Throughout the execution phase of my product developnent project, it should be an additional 9011 of management to; ( Create an atmosphere which fosters teamwork between the functions Involved. I Ensure that the product developer has recess to ~Ddetn tools ad methods (e,g , cigarette design models, conputer12ed data analysis, ete,)l ed 111 relevant information necessary to meet the objective. ( Ensure support frorP other functions such as Research, Engineering, Market Research, etc, PRWUCTIOHleOmERelAUZRTIOH OF FINAL PROtOTYPE Production of prototypes to be used in the final consumer product testing should take place in the factory and be of sufficient scale to produce a product which will be reprerentlti ve of full·rcale production, Because of the variability in both pilot and factory production, It is recommended that both prototype and CPT productlons be replicated, Production of final prototypes Is best managed by a team comprised of members from RAD, Manufacturing (Production and quality Control), ad Engineering, The function of this team is to: Review the product specifications prior to manufacture, ( Hutally determine the guideIlnes and procedures to be followed during the production, and to establish procedures for ensuring the integrity d materials to be used in the prototype productlon~ ·21· Clit; PDF -!::!!::!!::!.f3 StlC.i: Dill ~ Monitor the production and provide technical support for questions that arise. While monitoring, special note is taken of difficulties, issues or special requirements introduced by the new formulation, ,Assess the produced prototypes for adherence to agreed upon specifications and criteria, The product development process Is not complete until the product and product technologies have been effectively transferred into consistent manufacture and conrmercialited, Following successful consumer test results, the same team is used for the final prototype production and ideally the responsible Marketing function personnel, coordinate and oversee the initial full·nle eolnrrcill production of the product Prior to the first full·sc~le production, the team should review the analytical and production data from the factory production of the consumer product test. Data should be reviewed for adherence to specifications, degrees of variance within the production run, special material handling requirements, the suitability of previously established guidelines compared to production process ap~biltties, etc, In a written format, the team should also: I Establish a plan and criteria for ensuring the integrity of all materials to be used, and for assessing the Integrity of the final product. I Establish guidelines and procedures to be followed during the initial production runs, particularly if those guidelines deviate from standard practices for established products. I Establish the accountabilities far the monitoring and assessment of the Initial production runs. After producing the above document, the team should meet with the appropriate Manufacturing and Engineering personnel to review the plan and to incorporate any additional input. It's important that the plan be reviewed and ratified not only by the production management, but by key production workers and area leaders as well. Sufficient and appropriate personnel should be present during the Initial production run to ensure adherence to the above guidelines and to provide technical support for issues and problems which may arise, The initial production should be held for shipment until a thorough review of its adherence to specifications is conducted. In addition to analytical measures, a sensory assessment of the initial production should be made by expert smokers comparing it to the product which us successfully consumer product tested, Following the initial production, a meeting with key factory personnel should be conducted to review the operational aspects of the production and the suitability of the guidelines set forth by the team. With mutual agreement, guidelines may be altered for subsequent production. The above overall product development process is designed to maximize the probability of success of development projects, Following these guidelines increases the likelihood of meeting mutually agreed product objectives while optimizing decis~on·mlking, communication, the integration and utilization of resources, and the integrity of the product through caercl~l tzatlon, ·22· Clit; PDF -!::!!::!!::!.f3 StlC.i: Dill "'~ * .. ...~ · ·· ·~ ~IL-. ~.c· L rl ' ' "' . s. I~ "'~nlrt ~·~z~~ ·7 ·~ ''5·. ·-rvs*r~·:Y1~· ·*-· ~1 ·· · I··--·- u~~~·~· r I ~~,.,S~~L1T?lr~ii~~ 4\"JFCIP,,~~, .-LT -) ~fh~ r.·r,;*LI·· ,C I~:rrC,FBh:, ~· e·'BrP~~` .i C ,O. .;e ·U " : I 1~ i. ~p~~ ~1~~1~~ ~I r i n$9 C= i:Td~t- Sa··-~- · hi rluJ4Fi~n!~ ,· ·~" · =: J·- Yh~i~9 1-; *L I~ ~y~ t:, uy u F'i~Y L40LY~4R~Z 1.: E' :j =· " (~F ~· *r i r I·~·Jr e~'~S. b SYI ··~r *2: CTa L* C dYLL ~I )~5; I ~~' ~~·'"~'-"~'UL~t~'~·'r*~-~k~X~:l~?li~lYI~?*~L~O~!~~ r~~~lLltr~~~rl ·~:u~i~ - .IE 'i~TT C~~ ;Ffi~~! 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CRITICAL USIB PRIMARY PROCESSOPERAnONS ~PB0~99P Best practices for many process operations ranging Iron Green lear threshing to Pneumatic Conveying are conoon for both Virginia md blended ciglrettel~ The critical extra opefat ions for USIB cigarettes are casing preparation ed application, cased led drying and flavor application, The discussion here concentntes on these areas and cut tobacco drying, Appendix 2 contains information on the other common operatlonr~ eBP~f~S, Reeamnendations for the best processing are made baled on current knowledge, where there is a Ilkelihood for product improvement based on alternate e~uipsent or operating ps~eten,· recoienendatloa for this worlr are made. CaSlnP_PteDantlon: Easing preparation can be cMnplex, depending on whether cooking Indlor reaction steps are necessary. If so, 'elose control of time and temperature profiles is necessary. Another cs~licatlon is the scale up from bench to factory scale. When mixing or cooking a casing on the bench scale, temperature variations and mixing can be controlled vary precisely. Honever, when preparing the casings on a pilot or factory scale, this central Is lore difficult. for this reason, it is very important that the product developer who designs the easing indicate the important preparation parameters to those preparing the casing in the pilot plant or hctofy, This would include cooking times and temperatures any ingredients that are suspended rather than dissolved, maximum heating ji~nes, and any other parameters which might affect easing performance. bSlnP~DD1 fCatiOll: The function of casing application is to apply the casing solution pr suspension to the tobacco In a uniform manner, It lust be applied such that its effectiveness is Is designed by the product developer. This means that those casing properties found to be critical must be maintained. This may lean that 1 given temperature or nixing status must be dntlined. Uniformity should be maintained such that the tobacco receiver within 10X of the target amount of raring throughout a strip bitch. ThlE is 1 general tolerance though, and specific casings Ray require closer control. The best control can usually be maintained by Slaying the casing flow to tobacco flow via automatic control aquipent, Another function of eating is to raise the moisture content of the strip tobacco to a proper level for smooth cutting. A moisture content of approximately 21X is best for cutting. The method used to spray the eaJ1ng Is very important for uniform application to the tob#eo, Yery fine droplets are necessary to achieve this, and the only type of nozzle that has been found to be effective is In atomiting atle. Either air or steam can be used as the dmniling fluid. cautions are necessary for each of these, however, Yhen using air, .23- Clil; PDF -!::!!::!!::!.f3 StlC.i: Dill -·C-·C~ submit the tobacco to a high temperature (150-160'C) when the moirture is lower (44611. Therefore, the profile they recommend is Is follows: 80 · 100 · 120 · 130 · 1501160'C Moisture content It exit 11·4 The tunnel dryer, while standard in the tobvea and food industry is i very poor perfarmar in teres of drying. Hoidun variability Is quite high relative to other techntques end Improvslnent is needed, The Inpcrtst factors In the eased leaf dryer are the time and tempenture profile, and the amount of water 8vlponted, b study of other dryer typer which would use similar time ed tempentun profiles should be undertaken. The objective would be to simulate current sensory effectsl while Iqroving product unlfornlty, Yfth all this In o~lnd, , ;,tarting place for product developrant is needed, While there II likely to he ouch disagreement on the proper opet~inq~~l~ specifications, the fellowing has worked well, 'It is based on experlaenrr which yielded the best BbX products to date to compete with Halbaro. Inlet Redryer: 28·322 Moisture Cooling Sectf on: 6 f 3~ Moisture Exit Redryer: 14-1BX Moisture eutlamina otvms; Xhile the processing function of the rut l~rminl dryer is to reduce the moisture content from that suitlble for cutting to a level suitable for cigarette making the tobacco is once again subjected to a heat treatment, Thus, there is u;ldoubtedly a chenlcal and sensory effect on the tobaceo~ There are two main typer of cut tobacco dryers used In the tobacco Industry, the air dryer and the rotary drier. There are easily measured phyrlcaldifferenrer in the tobacco dried by these techniques. The air dryer yields tobacco with higher fiIllng power, due to better unfolding of the particles, and some Lstiffening' of the cut tobacco. It generally produces a larger particle r~ze, although operating paraneters of the two drying techniques can care some overlap in this ~elrure, In general, the higher the humidity of the drying air in either method, the better the particle she and fill value, If using an air dryer, the apparent nest important factors dfectiml physical properties Ire the moisture of the incoming tobacco and the humidity af the drying air, For maximizing physical pulllty, It should be maintained It 1 wet·bulb tenpentvre of 210'F (9g'C), The least well understood differences are In sensory effects. etu has found no sensory effeetl when comparing rotary to air drying" However, the longer tise of heat treatment in rotary drying aid be utilized to produce such an effect, or perhlps to reduce an effect. Both types of dryers are used in the Group, but eompanles use either one, or the other. It is important to optimlre, therefore, the dryer parameters for the current installed eeuipa~ent for near tena developments, .25. Clit; PDF -!::!!::!!::!.f3 StlC.i: Dill ion never PrePantlon and lopllelth: 'The discussion on top flavor prep~ratlon Is virtually the same as that of casing preparation, ~he spulpnent used must achieve the same results as the bench scale pnparlttan used In product develcpllent, care n~ust be taken In scale up to ensure that a full scale flavor is identical to the bench scale flavor, ApptldlPn can be done batehnise, but the best unlfondty Is seen In a eantfnuous rotating cylinder with Itglred flavor ~pplidlon (very s1Pilar tO earing Ippllc~lon), Al with casing ~pptlatlon, the flavoring now should be slaved to tobacco now via automated controls, Again, variation in flavor application should not exceed lot, This discussion has focussed on flavorings for nonaenthol cigarettes, as the work we se fpcu~sing~ an Is far 1 superior nontl~nthol pnduct, However, other techniques have been developed for menthol application, including ~elted nenthcl ~ppllatlon at the cigarette laker, and Renf?cJ .... application to pack foil, Any ot these tecbnlgues are suitable, Blend bulk~ng after flavor appllation Is necessary to ensure uniform flavoring in the final cigarette, Some period of time between flavor application and cigarette nanufidufe 1J~dvlJlble. Shis allows Jltlle finer components time to migrate throughout the tobacco to enhance uniformity, ·26· Clit; PDF -!::!!::!!::!.f3 StlC.i: 0111 C: I i I; PDF -!::!!::!!::!.f3 StlC.i: 0111 1, eR0011CJJ FQBMULATI~ON OYIRVI~ Although the following sections discuss formulation In terms of major components, leaf, by·produets casing and flavor, and design, the foraulltlail of IIUSrB productlmust be considered Is 1 vholh, leaf blend is affected by the type and mount of Root technology available, Casing may Or may not be used to introduce Root technology. Special flavors, (such as ORPIRV from Soun Cruz), are necessary If quality oriental tobacco is unavailable, Cigarette design itself, particularly at lower deliveries, influences the optimum fluelburley ratio. Ftucburley ratios also depend on the relative amounts of finer and filler tobaccos of each style, and If used, the expandad tobacco blind, Also, as discussed above, the special and unique primary process steps for USrB products interact stro?gly with blend and casino, For there reasons all specialist functions involved In the product development must work as 1 telll from the start, Additionally, since many variables may be involved, good statistical experimental design can increase the information derived from evaluation of the prototypes. Further, robust designs should be sought which minimize the effects of raw materials variability and account far process capabilities, It is In areas such as this that Hanuf~~turinglEngineeFing Core Team representation is so valuable. The groups providing essential support services, sample production, analytical and sensory evaluation, and regulatory approval need early briefing, not only for their own resource allocation, but also to obtain their expertise and input to the project, In praetlce, lost projects will eontdn both npuentlal IserilJ) and parallel development piths. The challenge for the Planning bnlger is to avoid redundancy and waste of resources while ensuring that promising leads are followed and schedule maintained, He cannot do this on his own, but only with the combined expertise of the team, There is no right way for all projects, but for a given project in I specific environment there will be a best way, LEAF_ BLEND U,S, blended cigarettes contain flue-cured, burley, and oriental tobaccos, and should contain by-products In the form of reconstituted and stem, and Root technology, Expanded tobacco may or may not be Included, U,S, blended cigarettes Ire marketed around the world. In many countries, U,S, type blends may reflect local taste influences, In these countries, a V~S~ blended cigarette AllY Include obvious finer notes contributed by the raw material, casing, or finer, This Is In contrast to the true U,S, International brand where the U,S, domestic or export version is the gold Standard. The development of 1 U,S, blend requirer the blending or mixing of different grades of each of the tobaccos, as well as the use of proper levels of reconstituted, stem, and/or expanded tobacco, ·27· .C· Clit; PDF -!::!!::!!::!.f3 StlC.i: 0111 Blsndll~tslr~: Ilrel: I le~f blender begins by reviewing the Induct grief. This will include the t~~lt product, ~n~ytft~ figures (tor end nicotine), end the productstyleldeslg? (len9th, circumference, ~t~). This informltion gives the blender the blslcs for beginning the process, ~e2: Tbs second step 1Prolr~~l thorough evllrltion of the tl~st )roduct in order to lelrn is much Is felstble IbPt the tlrget, subjective Iv~lu~lon of the tlrget is the first pert of thir~ lisIcllly, the blender, or rdeolly I smell group of blenders, In conjunction with other product experts, will be essesslng the product for tlste cherecteristics, Ilp~e~ hlrshnesslirritltion uuthfecl, end 1~ unique n eror notes, The next pert Is In in-depth ~n~yttc~ fnvestlsetlon of the pFoduet, This will Include routine end nonroutlne chamlcil mllyscr thlt cen help In product development. The nonroutlna lnllyses will be more In depth to support routine m~ysrs end sensory Isserslent, end should give specific guidmee In undcrstlnding the technologies used in the tlrget product. Following ere solne of the key routine ~nllylsl, ( Blend Alkllold · This glves In Indlcetlon of blind strength, proportion of fllvor tobeccos versus filler tobeccos, ( Suglrs - This con give on Indlcltian of blend style or nf~ I higher lug~ level cln Indicltel ~ul·cun~o~lntll skewed blend, whenell low suglr content cln Indlclte 1 higher burley content. It Is Iqottmt to remember suglr Is Iddld In the clsing, ons needs to review other enllytlcel figures before drewlng conclusion from suglr mllysls, I Nltnte · A higher nltntl content Indic~er higher bu~cy or hurley stem inclusion. (Hltrlte end lu91r levels should be conplred to look for trends), I konll · This will give en Indtcltlon of Idded llnonie Ilv~t, Blend Seplrltlon · A brclYw of 1eI1nI, d~rt reconstituted, light reconstituted, stem, end expended tobecco II given, I TIr/Nicotine Aetio · if 1 high terlnicotine retlo 15 seen, this mey be en Indlcl~on of high o~ent~ Inelusfo~ if 1 low tdnlcotine rrtio 11 seen, especfllly In conjunctton with I high blend elkelold, one would expect the use of some rlther high nicotine tobeccol, I puff Number · This will provide delivery per puff Infonlt~n~ low puff number gcner~ly Indlcltes 1 high level of exploded toblcco, end design influence, ·28· ClibPDF - v~~fastio.soni (Oonsity · If the density Is low this indicates there Is some process to reduce tablrca weight (i.e., eu;mded tobaccos, Hm pmcee, end rtm expansion), e Pressure Orop · This n~~y '1ve some expImltlon for certain smoke attributes. For exunple, f a cfgarerte ha 1 high filter pressure drop, the r~sob will probably be thin and dry. Therefore, the high fitter pressure drop lay rePunt for this rather than the blend, I elgarette Piper · Cltnte or Acetate Additivel This will explain certain taste ch~ncterlstlcJ. nigh piper porosity can cause the sloke to be thin, dry, and t~lt~ting~rhlrp, Yentllatfon · High ventflatlon can also cause the sloke to be thin and dry. Also, ventilation In~full flavor cigarette lay be indicative of a strong blend. ( Tipping Length · this will give an indication If design is being used to alter delivery (l,e,, longer ttoping can indicate that design is being used to lower the delivery of a stronger blend). I filter Length/Tobacco Section length .This relationship will also give an indication of design influence on delivey, A longer filter length can Indicate that filter length is being used to lower the delivery, ( Hovel or unique design, such as the BARCLAY filter or the Dual Ehrnber Filter can have a slgnlflcant effect on the snake character. A blender must be aware of these effects in order to address effects on smoke pualltY, After the thorough review of the target product, review of the In·house portfolio of blends is lade to detenine if my current blend is close to the target product. Zteo 3: Blend Oeveloolaent This is the initial step in blend design. This step is done in the lab with hand·lade cigarettes, ~4ez: I Review contribution of individual grades to sloke character (i,e·l flnor;lmoud and quzlityl sweetness, irritation) end/ar dellverier. - Lke Character · AeconpliJhed through wbjective aoke evaluation of individual grades or through experience, Oeliveries · Review analytical figures of annual grade analyses, ·2g· Clit; PDF -!::!!::!!::!.f3 StlC.i: 0111 Blend in: 1 If there is 1 central blend established from the company's portfolio, blend development will be based on this~ if blends in the current Ilo do not nerlt con Ideration, a blend is developed from There are two accepted practices of blend devalopnt. One Involves develop i" the blend bY Indtvldu~1 grades In the whole blend (rel Athod 1 below This nathod involves trial and smr evaluation on 1 whole blend basis, Md 1 blender will make adjustnentJ in individual grades or component totals based on the subjective evaluation. Far exaple, if the blend has too much burley character, one lay reduce the total mcunt of burley pr My reduce the total Mount of barley flavor grades and increase burley filler grades The second method Inwlves developing the blend by developinglach component blend. This method Involves trill and error evaluation for each component blend (fiue·cured, bwley, oriental) and then blending the cornponent blends together and evaluating the whole blend, For this method, a blender will make adjustments In individual grades within a component as one is developing that component blend (i,e,, adjusting the Mount of flavor vs, filler grades), and then Rake adjustments to the component totals when developing the whole blend (f,e,, adjusting fiue·cured/hurley ratio, Mount of oriental, etc.). Either way is acceptable ·· it depends on historical practices and 1 blender's preference, Details of the two blending methods are as follows: MethPbl · Record on piper grade choices, Md assign Inclusion levels for the whole blend, This will include flue·cured, burley and oriental tobaccos, reconstituted and stem (20 to 258 total by·products], and may include expanded tobacco (·1OIC Inclusion), · Reviewlcrltlpue the written blend based on experience and knowledge of grades and develop alternative blend(s] generally 3·5, on paper, based on knowledge of target product, and not just 'ntch", but better, · Prepare h~nd·llde blends and unfiltered or filtered cigarettes In the lab and subjectively evaluate by Led Expert Sn#kefs (~lnlPun of 3)~ · Repeat process as necessary from. beginning of Step 3, ·30· Clit; PDF -!::!!::!!::!.f3 StlC.i: 0111 Method 2 - Record on piper grade choices, and assign Inclusion levels for each component blend, - Revlewlerltfgue the mitten component blends based on experience and knowledge of grades end develop alternatives, generally 6-8, on paler, · prepare hnd·mlde component blends and unf)tered or filtered cigarettes In the lab, (Note: A Specific cigarette spill designed For the project may be used), Flue-cured is generally the first component blond developed, followed by burley, and then oriental, These components are evaluated by leaf Expert~Sokersl and 1·2 blends per component ire selected, Note: The burley component blends are sometimes diluted with a eomnon fius-cured blend due to the strength, · 1Rer levolaplng the tolaponent blends the next phaa is blending the components together beginning with nue-cured/burley ratio and then adding oriental. RecPnrtituted, stem (20·2511 total by-products), ad possibly B ('lbX) are then added, Again, this evaluation is done by a minimum of 3 Leaf Expert Smokers, Bv-Produ~s_and Exo~dJ_Tobacco · Stem (In the form of expended stem) and ET are ~teri~lr used to lower cigarette density and alter per puff deliveries. There may be used in combination or separately to accomplish this, also stem along with reconstituted tobacco, is used in order to fully utj lire by·produets, On average, to to 25~ of the blend consists of reconstituted and stem, The contribution of there materials to the bland character reflects reconstituted or Item additives v;well as the combination of there materials, Note onAo4t Sechnolnlul: poot technology Is I key in U.S, blended products, Root technology can be incorporated into a blend via reconstituted tobacco or through easing additives, With the introduction of Root technology in reconstituted, it ha become 1 significant contributor to smoke qni ity, Where used, CPC1 (bindcast recon) Is a critical blend con~onent for Its tute contribution and amelioration effeet~, A standard reconstituted Fixture in blends is 60X EER (paper recon) and llD [PCL (band east) with a n~~inum blend inclusion Of lm CPCL, The other method of utilizing Root technology Is through casing. Ar 1 casing, it an be applied on specific parts of the blend, such Is stems CLO burley, etc, (See Rest practices: by·prDducts/RPot technology for more information), ·31· Clit; PDF -!::!!::!!::!.f3 StlC.i: Dill Steo a: Evaluation of8lend OevrlomcRnt_ ( Fine·tune blend(s) From subjective evaluation and/or eliminate candidates, ( Review availability of grades included in bland, I Calculate blend alkaloids and co~npare to target, · Calculate blend cost. · per kilo or pound basis, · per 1,000 cigarettes basis, ( Repeat Step 3, If necerJary, to address availability, price or blend atkaloid concerns, I Results: 2·4 blends for further evaluation. Step 5: ~ Introduce Blends to Other Praduet DevelPs~ea~ Exoerts I Hand·m~de cigarettes are evaluated by Product Experts (Ledl Caring, Flavor, or Oerign Experts) for blend evaluation and input. This also provides the earing flavor, and design experts an opportunity to evaluate the blend end Identify attributes for tWr vee of expertl se to address, Shis may he an individual evaluation pr a panel evaluation. SteP 6: Pilot~Plant · Produce Inwhrne·made cased/unflavored cigarettes. step 7:~ analytical Henurem4ltr I Routine analytical measurements of pilot plant elglrettes, SteP 8: Suhlectfve ~valuat~nns I Internal experts (product Experts), ( Select best candidates for further product development or identify changer needed which may include blend, caring, or design changes, · Hay need to repeat from Step 3 or Step 6 as neeesJary~ SteP4: Flavor DevetoDmen_t Blend(s) are then given to flavor expert for: v Flavor development. ( Evaluation and selection of flavored candidates (Product Experts)~ ·32· Clit; PDF -!::!!::!!::!.f3 StlC.i: 0111 Steo 1O: Pilot Plant I Produce oaehine·aade flavored candidates, Step 11: Analvttcal Measurements Routine analytical measurements of pilot plant cigarettes, Steo 12: Select Best candidates for CPT I Internal screening by PIP(UEt LXplltlj~ Oupont /BLU); Y1H (BQti). e Screening of samples by consumer pane I Recommend 1·3 products for CPT or repeat steps for improvement, mdfnp information an ewnPetftPc~ Host of the competitive information known relates to lad purchases (puantity and quality), and little is actually known about competitor's Best Practices of Leaf Blendlng~ Pn USA products (partieularly Marlboro) are the benchmark for U,S, tute chlracter, In some oarkets, PH Europe has adjusted the finer character of U,S, blends to European taste, but their products Ire converging, particularly with respect to deliveries, PM is believed to have few blends, and their products are developed or altered through process and recon chemistry flavor or design parameters, Some of the basic information concerning competitor's tobacco purchases include: PM USA and Europe purchase run of the crop, PW USA purchases the majority of their tobacco in the USA as BaW doer~ PH Europe like BAT European companies, purchase tobaos from nany countries, /M loaf durations are believed to be approximately 24 Ponths, I RJR has cut durations significantly and tend to base purchases on price, ~ Lorillad'f U.S, purchases are closer to BaW's than my other U,S, manufacturer, I Reeatspla buys middle stalk position and not tow stalk filler or tips, BY-PRODUCTS At the simplest level, by·products include stems and fines (both luina fines from threshlng and manufacturing fines), historically, by·product utilization has been ~n economic effort, with the pall of 100X utilization of tobacco materials, In practice this means tLt~ltl stem and fine materials will be modified for blend inclusion, This can range from 1 high level of stem inclusion, with 2·JX reconstituted to minimum stem levels with 18-22~ reconstituted tobacco, The total by-product level will be appraximately 20-2511 of the blend It 100rC utilization, based on 1 typical~ blended cigarette formula, ·33· Clit; PDF -!::!!::!!::!.f3 StlC.i: 0111 The balance between Item and reconstituted sheet is driven by several issuer, stem may be desirable for cigarette physical quality (fira~nesr and coal retention), processing economy, or density reduction. Reconstitution, on the other hand, yields a product with assured uniformity and tobacco led selnnce, and has less effect on cigarette pressure drop. However, In many cases, the investment in reconstitution professes can be capital intensive, We generally assume that our Intent Is total leaf purchase utilization, Every brand aly not represent perfect utilization, but the level of utilization required is the first step in reconstituted development or improvement. This wi11 form the basis of choosing a leaf fomula~ Al a first step, then, m estimate of the final blend stem inclusion level must be made. While total utilization has been the historical goal of by-product inclusion, over the years we have moved to recognizing the potential of using by-products Is ~~neanr of including improved sensory effeetl~ These saterlals provide one ae~ns of incorporating Root teehnology~ Both BhY and BATCF use by·produets to achieve total utilization as well as to Improve smoke quallty~ SteP Utilltatlp~ In many eases, reconstituted tobacco Is not economically feasible or is not available to the product develaper, In these instances, higher inclusion levels of processed stem are used, generally ranging from 12-22X. Within the RAT group, stem is generally expanded before use through 1 variety of known proeesses~ These include, YTS (vater treated stem), 50S (shredded dried stem), and StS (steaa treated stem), Stem should be expanded to obtain, at 1 ninilwm, a neutral effect on smoke quality while oaximlzlng physical puality/densitY opportunities, It is possible to obtain some Root technology while utilizing higher stem tevels~ At BATCF, this Root technology is obtained through additives to the Its such as EMERGE (1 reaction mixture which includes naturally occurring organic acids and ~nmonll, applied as 1 burley stem casing). At Souzl Cruz, 1 more coaplete use of Root technology is achieved by combining the addition of anmonium salts arsonium tartrate, GAP, etc.) to the burleylflue cured ~ten with the additIon of the aomonil derived Reaction Flavors (ANSIRO ed QSPAU) to the flue-cured lamina portion of the blend, Thir ea~ined addition can provide significant smoke body smoothness and "Marlboro character' to the snoke if the products In which both additives Ire used. The approach used by Soura trul can be considered if there are restrictions of costs, production or legal regarding the use of reconstituted tobacco. There Is evidence that philip Morris uses additives to incorporate Root technology in Bn2il without using reconstituted tobacco, -34- Clil; PDF -!::!!::!!::!.f3 StlC.i: Dill Where reconstitution is readliy available, such Is It M, norunenthol blends contain 13·6X flue·cured stem level in the final blend. This stem level coupled with total utilization leads to a reconstituted leaf formula of approximately IOX stem and 30X lain~ fines, For both stem and lamiu, the burleylflus-fured ratio used in the reconstituted for~n~lltion will reflect materials ~valt~blllty, but will remain constant in the fanull~ (lamina fines Include 111 manufacturing fines, led threshing fines, and returned goods reclaim,) Menthol brands have historically used sts a a neutral diluent, In this capacity, stems have been used It the 10-1B level, with I similar level of reconstituted sheet using 1 relatively low level of stem. This approach aaxlnltcr the physiell quality advantages of Item. Recent menthol product development work has moved in the direction of nonmenthol philosophies of low levels of flue-cured stea and higher levels of reconstituted sheet, edified for sensory Inprovennnts. Reconstituted practices Reconstituted tobacco originated Is 1 further way to use tobacco by-products~od continues to sen that role, However, reconstituted tobacco is Increulngly recognized as In opportunity to improve smoke quality, in ways that cannot be achieved elsewhere, While all reconstituted grades are a form of by·product utilitltion and waste Ilvlngr, rgconrtftuted tobleeo ii now undentPad and nanaged to provide I value·added impact in smoking quality, At I minimum, reconstituted can be 1 neutral diluent; examples here Ire BaW PJS, BATCF RTS and DEER, ~lthaugh the latter two are typically used at only 3 to os inclusion levels, At the next level, reconstituted tobacco can be a diluent, but make certain positive contributions to the smoke at the same time. An exunple is EER, providing reduced nitrate ad mild Root technology in nonmenthol blends, Finally, reconstituted tobacco can make ~ significant and unique contribution to smoke. GPCL is the example here, e~Z~",d:olltffn,l~~:~significant Root technology, smoke body, smoothness, and Product Oevelopment and the use of reconstituted tobaccos in new products or product improvements reed res careful consideration of the role the reconstituted grade is to play. For the future, reconstituted tobacco needs to be integrally considered in blend, casing, ad flavor development to the extent that we now view critical leaf components. Reconstituted tobacco is a building block to superior products and its use must be one of the earliest considerations in our overall product development proceJs~ In developing the ovenll furnish formula for various reconstituted tobaccos, the degree of desired Root technology as well Is the available reconstituted manufacturing options and the desired stem levels should be considered, Beeuse of the sugars inherent in fiue·cured stem or scrap and the sugars available in manufacturing finer, these materials are good sources of furnish for ammonia containing reconstituted gndes~ In addition, the burley stens and scrap an be readilY used in a paper·type process where the renovll of nitrates can conventently be ~Ecomplished, The next step is to make a conscious decision about the expected contributions of reconstituted tobacco to the bland under development, .35. Clit; PDF -!::!!::!!::!.f3 StlC.i: Dill A, Ic~t~t 91t~t If the purpose of the reconstituted grade is solely by·product utilization, the goal will be nlnfnum contribution to smoke pallty, Oepending on the situation, this could be frue far bath menthol and nonnenthol brands, With menthol products, the emphasis IJ on menthol perception and clean taste, Tobacco taste Is 1 subtle effect and distinct taste contributions from the reconstituted tobacco are not appropriate, The reeonstltuted grade alone should exhibit a bland tate with minimum irritation, These attributes will allow the reconstituted tobacco to 'dilute" the tobacco tute and nicotine delivery,'laking roon' far the menthol taste, The neutral dlluent reconstituted tobacco will likely have only glycerin added to improve fflofrture retention and to improve sheet pliability. Inorganic fillers such Is carbonates or chalk have been explored, but only on an experimental basis, A similar approach may be possible far certain nonmenthol blends where tate ~ndior Root technology Ire accomplished by alternate means. For example, BATCF currentlY uses reconstituted tobacco as manufacturing waste utilit~tian. RTS Is manufactured a an extruded product using about 50X each sanufacturlnp fines and winnowert, RTS contains pectin as a binder sarbltol as the huseetant (fnstead of glycerln), and some cuing-type~~ddit~ver ~s taste modifiers. This grade is used In domestic Germn brands at 2-3X inclusion, The German use of reconstituted tobacco is within the neutral additive philosophy, The current goal is manufacturing Haste utilization with minimum effect on the smoke quality ad use of stem via the SE process, BATCF currently aPPIles A~at teehnol'ogy as ~ casing treatment, available for specific blend components or the whole blend. Reconstituted tobacco is not 1 primary vehicle for poot technology, Current research on reconstituted tobacco is directed toward tute improvement and filling power Improvement, B, Ileutral0lluent~ith bl_tive ~trlbdes In addition to the neutnl filler role, there are opportunities for specific improvements without loving to dominant taste characteristics, Since the reconstituted leaf formula has a significant stem level. the reconstitution process offers 1 chance for blend nitrate reduction, particularly If there is a large amount of burley sten involved. Burley stem contains 8 to 1ZX nitrate by weight Separate extraction of the burley Item permits the discard of 111 ora portion of the burley stem solubles and thus the nitrate, The result will be a lower delivery of nitrogen oxides in smoke, This approach can be used for menthol or noncenthol blends. -36- Clil; PDF -!::!!::!!::!.f3 StlC.i: Dill For nonmentho1 blends, there is opportunity for mild to moderate Lot technology. Moderate process conditions lead to same degree of ruglr·~mPnla chemistry and the reconstituted sheet functions as a carrier for urrmonta to be relelsed during eoPbustlan~ The degree of Root technology Is Influenced by the ammonia source or sources used, the process point of addition, and the added sugars. Ar with 1 target of neutral effects, glycerin will be added a a hunectant. Additional additives my Include different sugar sources and traditional casing Ingredients, although the effect of casings has not been Is great as might be expectedl The most co~nnon ammonia source is dlurmoniun phosphate (OAP) though direct treatment with unaonla or annonll ad phosphoric acid Ire also viable. urea is also I potential Additive which can be used in eomblnltion with DAP, G, S1PntTlent Taste Cot~Elbutar Far nonnenthol products, reconstituted toblcca offers the possibility for unique smoke quality contributions. Extensive Root technology, combining sug~rla~nnonil reactions, biopolyeler modification, and residual ammonia, can contribute body smoothness, ed burley character to the smoke, In our current under;tandIng of these reactions, we Ire able to achieve this level of Root technology only in the bmdart process. Soota Cruz is working on Root technology incorporation to DEER, preliminary results having shown that the incorporation of ANSIRO, CESPAU, aaonium tartrate, or even OAF to OELR affects, in a positive way, the srganoleptic characteristics of the products which incorporate O~ P~rf eal_pualttv contributor Smoke quality will always dominate the reconstituted development work, but the reconstituted grade genenlly will represent up to 2oX of the blend, and physical quality anot be ignored. Traditionally, we have thought of reconstituted theet gullity in terms of "strength". As 1 blend component however, pliability (md thus particle survivability) may be nora important than strength. Tao much strength, for exargle, can cause cutter flagging, and too little strength can cause particle breakup. For paper reconstitution processer a high stem formula will provide ideal sheet, If the led enough fiber to make an adequate, If less tnan formula is Imina-skewed, or If inert fillers are added, sone natural fiber addition (ruch as wood pulp) may be required. Addition levels will range from 3 to ins, depending on the Its level~ Whether fiber is added or not, the sheet quality will be very dependent on the refining skills of the converter, For band·tlJt processes the preferred route is chemical and thermo·mechanleal release of pectin~ The solubiltzed pecttn will act as 1 binder and form a film on the band, making 1 sheet with good physical integrity, Rglin, refining is an influential factor. Refined whole stems will produce 1 more fibrous, and thus stronger, sheet than refined ground rtems~ -37- Clil; PDF -!::!!::!!::!.f3 StlC.i: Dill Han·toblcco binders such Is carboxy methyl cellulose (CMC) can be used for both piper and band·elst physical qu!lity inprovenents~ however, these types of additives are traditionally not used in the U,S~ Peket due to sensory issues, pill value of reconstituted tobacco is not treated as a developmental Poai ~ The filling power is largely detenined by the tile sloke quality and physical gullity have been addressed. O~B can be used to improve cigarette physical quality, through the reconstitution of fines ad other by-products, In companies where the conventional processes of reconstitution (bmd·elrt and piper type) Ire not economically prpflt~bte, As a function of the potential of the OEER process, SoUZa CWX W111 continue its development with the objeetlve of incorporation of Root technology and reconstitution of by·prpductr. ellarette B1Pnd Develoomen_t Ideally, the preceding issues se addressed It the beginning of I project, and several new reconstituted tobaccos Ire developed or existing reconstituted grades are chosen as candidates, The reconstituted candidates Ire then elevated to grade status, and ue available to the leaf blenders for total blend development. ~n practice, the project objectives and timing will dictate that an existing reconstituted grade or a first-cut experimental grade be used for preliminary blend development. Reconstituted developplent can also proceed concurrently, attempting to improve on the Itating point. A, Use_ln Ilenthol dnd Nonnenthot Products The importance of defining the role reconstituted tobacco is to plaY in a developmental blend cannot be overemphasized. The reconstituted grades will sake up a s i~nifleant fraction of the blend and will influence the smoke quality In at least as great a proportion. Reconstituted development or improvement oust take direction from Product Oevelopnent and Leaf Blending needs and expectltlonsl Once identified, reconstituted grade candidates nuJt be considered in the basic blend development, and in casing and flavor work. Only with this kind of interaction can reconstituted tobacco be used to its full potential. levels of use far neonstituted tobacco Ire I function of by-product utilization up to the point that Root technology or any other taste attribute becomes significant~ At that point, there must be 1 search for an optimum level or optimum combination of recpnrtttuted tobaccos. PJS and RTS, for ewanple se used in the neutral diluent philosophy, stem levels and PJS/RTS ievels may be varied independently, and the reconstituted grade is not I major factor In the development of the blend fluelburley ratio, EER will, however, Influence the blend fluelburley ratio since Its use of mild Root technology will result in noticeable smoke quality contribution. -38- Clil; PDF -!::!!::!!::!.f3 StlC.i: Dill For CPCL, with its Inherently high level of Root technology, major blend shifts may be necessaryl Specifically, the CPCL will provide substantial burley character to the spoke~ To maintain the desired blended tute, It will be necessary to shift the fluelburley ratio of the lamina toward the nut-cured side, further, we have found that there Is an optimum level far CPCL, Too little will not achieve the desired effects and too much will be overpowering, Our current practice Is to use CPCL In combination with EER, in EER to CPCL ratios of 1:1 to 2:1, 8, Ivaluatian Sensory feedback for reconstituted tobacco development will cone from leaf blending and from internal sensory panels, While some key experts wilt smoke the reconstituted grades straight, most smokers prefer to evaluate hnd·mmde cigarettes with 10·20X reconstituted In 1 base blend, This allows screening of experimental candidates, Once promising reconstituted tobaccos are identified, production cigarettes can be made in a pilot plant for Internal and external sensory evaluation, For any reconstituted tobacco incorporating Root technology, It Is Important to recognize aging effects, First, the reconstituted product Itself lay require aging, CPCL is aged for 4 weeks before use In production, Even with experienced smokers, 1 to 2 weeks aging is necesslry, Second, the finished cigarette requires a period of time for reaction and migration processes, One week is minimum for internal evaluation, longer periods of aging (e,g,, 3-4 weeks), comparable to the market place Ire needed for external sensory testing, -39- Clil; PDF -!::!!::!!::!.f3 StlC.i: 0111 11,5, Pal~nIIE M~I~ All U,S, complnies ire lssumed to strive for totll utlllt~tlan, PH Is suspected of over-utllltitlon, but thlt Is difficult to prove, end miy only represent a different vlaw ol whet constitutes '~·pr~uetsl, We hive little Infonltlon lbout the reeon~tttutld toblcco development process or the blend development process it competitive compinies, phi.Uo Horris pii uses 1 steidy ar flue-cured stem II their blends, All other by-products ire presumed to go to reconstituted products, ill olnufectured ~ m, PH also maintains 1 bland of piper and hand-cast reconstituted In nonronthol blends, The rltlo is currently 75;25 piper to bind-cist, rhe bind-cist ippeers to be held by PH is i key pirt of their blend design, end Is g~nsnlly recognlred is such by their colpetltorr, The piper reconstituted toblcco contlfns urel end MI; the bend-cast product i1e ~Pll~nf~ nlctlon proccll ouch like ePC1, pM uses I ndnennonieted piper reconstituted grade, and no bnd·Elr~ In Mlrlbarn Icnth~ This is consistent with our understlndln4 of menthol reconstituted Is i nautnl filter, R, LBmoUI UR does not use Included stem, All by-products ire issumed to be converted to 1 piper-type reconstituted tobacco In the RJR plint, RJR If known to hive trelted the finished reconstituted sheet with ~nf~ Recent pltent Ictivltles suggest m effort to treit the toblcco extricts with enmonii ind/or MP during the reconstitution process, lorlllerd Lorllllrd Ilso does not u~~ stem, converting ill by-products to piper reconstituted tnbecep fran K1Jl~y·~~~ We believe they use only one grilde Icross ill brlnds This grede contllns phosphlte blck·c~c~~tld to aoproxieetely 2X added GAP, ~~ls Is ~leon~st~nt with the hlstorlcll use of DAP In menthol products In the U,S, mlrket, kdc~n krleln mlnuflctures their own piper reconstituted tobicco, In it Ieist two grldes, One of the grides Includes DRP, U99~t~ Uggett also obtllns pepar reconstituted tobeceo fra ~nbe~y-Ulrk. Ue have seen no evidence of unnonie ehemistry, se we presume this product II simply by-product utllltltlon, ClibPDF - v~~fastio.soni Em~ilLeOLIIElmVL ppsOucEr Ibllio krrlr ph uses e e~llltlon of two trCes of paper neolrtltrtld toblcco in ell hrlnds, wtth the exception of one ultrl low tlr br~d, Ons of the piper sheets eont~lll roll~ted reaction products end the other does not, Ihe blend inclusion level is dap~ndmt on the tlr dellvart~s, nngfng frao ~ba~ 2m InclullPn fDr full Rlvar to lbout 6X Ineludon for low tir products, Str inclusion vlrtes frp 6 to 10X, 1~~111 Latl~~ uses one Oteae of nonumonIeted piper reconstituted sheet et 5-5X Ineluslon. Stat Is used In the bland st 15·2~ inclusion, Mlrtin Idl~ll (Lt~l) Ilttln Irflhna also usese single grda of Poarolrltld piper raconstltutcd, Inclusion level Is 5-7X, Std II used st 15·2m Inclusfon, R,J,Awolds R31 uses ronf~tcd peCer reconstituted sheet st 13·tl inclusion, 5tlns ore used up to 10X inclusion. -11· ClibPDF - v~~fastio.soni __ eAS~6 BtlDIlAV4RIBf IHtRPDUCTION Caring and flavor play a very crucial role in the commercial success of 1 product, Their part In total product development Is of growing Importance due to reasons like: I Tobacco quallty~lvailabill ty, I Modem process technologies and manufacturing practices, I Consumer expectations, · Envlron~entaI Aegul~tfons Ia~~x, delrveries earing and finer can contribute in the following aspects; I Correcting blend chemistry deficits, · Protecting against negative processing Influences, ( Suppressing negative taste effects (blend, design, packaging). I Upgrading tobacco and tobacco by-products, ( Enhancing specific tobacco notes, I Introducing Root technology (liquid recon), · Achieving product identity, Casing and flavor can be a very versatile pat of the product by impmving smoke quality without noticeable effects on tar and nicotine deliveries, Flavor In general and clsi ;19 and finer for tob~ceo particularly is a high expertise matter, The quality of their contribution depends an the expertise available, Different local situations may lead to differences in approach, These differences can be in the area of expertise and/or availability of flavor materials but also be caused by differences in market demands: from the English type Virginia markets such Is UK, Canada, Australia, and certain other countries where contributions from casing and flavor will remain subtle to the Southeast Asian markets such as Korea, Indonesia, etc, where flavors dominate over the tobacco taste, In the major markets U,S, South America, Europe etc, the casings and flavors are designed to e;lhance true tobacco t~ll~e and)provide a "signature" to the product. For menthol products, although menthol dominates the top flavor, menthol "modifiers" to enhance taste and flavor are becoming increasingly important In various parts of the world including the U,S, ·42- Clil; PDF -!::!!::!!::!.f3 StlC.i: 0111 Casing and flavor, being an integral part of a product cannot be developed In isolation, They should be integrated with the overall product development plan, As such, casing and flavor development should follow the following process flow: A. Objectfve Phase B, Prototype Development Phase C, Prototype Production and Evaluation A, OUactiua..lbs It should be recognized that easing and flavor are not panaceas for all product development problems, Unless there is 1 suitable blend and an appropriate cigarette design on which casing and flavor development can build, development of a successful product will be impossible, Therefore, in the objective development phase the casing and flavor development should be intimately tnvclved with other functions such Is Leaf, Process, Design, Marketing, etc, Through discussions with these groups, existing criteria and constraints are identified. Different product development targets require different approaches; e:g,, a line extension of an existing product Pay only need optimization of the existing casings and flavors, If an entirely new product needs to be developed more creative input has to be introduced. In any case, the following questions should be addressed: ~ What effects Ire desired/needed from Easing and flavor? Anticipated Blend. s Anticipated Design and expected deliveries (tarlnicotine), ( Anticipated Process (e~4~, burley redrying, expansion, etc,). s Target Smoker Group, ( Competitive Benchmark. B, PrototvPe DeveloPment Based on the information developed In the Objective Development Phase the easing and finer developer determines the preliminary "tools" that he needs to provide the described effects, To be able to make a proper selection, the maintenance of the casing and flavor stool box" has to be an ongoing effort, It should: I be extensive enough to meet demands, I be limited enough to handle properly, I contain only materials from reliable sources, I contain only materials which as recent, available, and in compliance with group and local legislative requirements, ·43 · Clit; PDF -!::!!::!!::!.f3 StlC.i: 0111 The selection can be supported by an IpprPprilte eolpbination of the following subjective and objective leaunments~ ( Sensory Ev~~ultiPn of the tlnlet product ·· What is the uniqueness of the benchmark product in tenns elf its sensory attributes! casing and flavor developers shouid also be able to Identify the distinctive finer cLneten In the smoke, such as, chocolate, spicy, fruity, floral, nutty, eounulnic, nlple, s8oky, honey, etc,, those arising from Root technology, and orlenta1 n~tes~ These nill form the basis for finer development. e Analytical Input from T~rgat Product ·· ~dommtion on additives such as cocoa, Ilcorice, sug~rs, amsonia, phosphate, etc. Suppienental data, such as cocoa butter fat, mote chemistry, will provide further clues on the type of additives used In the target product. Further, information on products of lugs·unnanil chemistry such as fructosltfnas, dooxyfrultolninel and pynliner will help In Identifying the type of Root technolapy, If any, the target product Fight have. ( Competitive intelligence. I Input fron all available sources: · suppliers · research · llteraturelpatents · group experience d sustainable source ~ust be located before experiaenting with I material, The costs have also to be considered before proceeding too far~ Since the sensory contribution of a material can be variable at different use levels and/or appllcation sites, materials should be evaluated separately using dIfferent levels and blend components as subrtrates~ It is not uncormnon that the sensory effect of In additive Is component Ipeeife, The chelirtty of such additives, if understood, helps to Identify the probable site where It night be mast effective. Far example, if the laterlll 15 an ;nmonia source, generally it works best by increasing the molar base ratio between different blend components Thus the annonla source has to be applied on stems, recon or the burley portions of the blend and not an the flue·rured/oricntal components 1 it Is important to determine the approximate use level not only to aptimite its effect on the smoke sensory quality but also to determine its regulatory status in certain atos~ The regulatory issues being a speciallted area ~re best handled by each company's additive or regulatory personnell If Root technology has to be incerponted, different eguivalent tools, such is, urrmonllted recon or ammoniated casings (ANSIRO, CESPAU, MLRtE) etc, have to be considered. The decision for choosing any of the router depends on the avlillbility, regulatory issues, smoke quality, costs, and the overall product concept, ·44· Clit; PDF -!::!!::!!::!.f3 StlC.i: Dill Yhen irritation reduction is required, Sours Cruz has some special products called ~nti·hafshners agents, which se mixtures of natural fruit extracts plus organic acids. These anti-harshness agents reduce the undesirable effects of irritation, harshness, and burning in the mouth, nose, throat tongue, and palate, a well as the sensation of bitterness in the cigvotte smoke. As a result, these improve the total smoke quality of flue· and air-cured tobaccos without, however, making the tobacco aromaltaste flat, as may occur when some acids alone such as, lactic, tartaric, and citric acids are utilized, For flue-cured tobacco, Sours Cwz has been using c6nmerelally the anti-harshness casings: BIARRO, ORR4IB, HrSBAD BREHCU, and LLOAIA, For air-cured tobacco, Soura Crur has been using comnerclatty the anti-harshness casings: LHATRO, PmNOZ, and R4HNEG, These casings are 100X soluble in cold or hot water and are compatible with the other, normal casing ingredients, The smoke sensory effects must be tested at different levels so a to adjust the Ilounts necessary for each type of tobacco utilized in the blend. having determined the materials, experiments should be designed that optimize the following: levels of Casing Additives I Combinations I Application Sites To Tllit the number of possible nmples farner experiences with materials and comhinatlons, regulations, and preliminary expert sloking evaluations have to be taken into account. Further, sites of application for certain additives may be kept fixed (e,g~, cocoa and liarice on burley), C,ProtPtuPe_Prod~U~·tlon aod~Evaluatlan Following the design of the casing experiments, prototypes should be made in the pilot plant, This assumes that the Leaf Group has developed suitable blend(s) and the ei garette Design Group has developed appropriate deslgn(s), The cigarettes should be made without using top flavor, These products are screened internally to identify the best eabination of additives, their levels and sites of application, The optilized product(s) will be used as the base for flavor developnent. -45· Clit; PDF -!::!!::!!::!.f3 StlC.i: 0111 fllvor development Is 1 blend of art and science. It is the flworist's sensory acuity that ultimately leads to development of 1 successful flavor, This work can be accomplished by combination of the following: ( Ftavortst's own memory of smoke sensory properties, I Ubnry of sensory information on nterllls evaluated over the yen. I Sensory Impressions of target product, I Analytical input, In some cares mllyses may Identify certain ingredients that give 1 clue to certain complementary flavors. By combining the above mentioned information the flaertrt develops his first set of compounded flavors, They are then introduced Into the appropriate cigarette blanks as developed previously incorporating optimized eJlng~blend ahd design, The Injected cigarettes may be evaluated after 24 hours to get the initial impression on the flavor and to get clues for further develaplnents, To determine true effects, the cigarettes should not be evaluated any I earlier than one week. Ihis process continues through repeat trills and evaluations till the product including flavor is well balanced and meets the demands, Once a flavor Is developed, In most eases more than one, the next step developed flavor(s) at a levePilot·pl~nt rncorpotlting the newly Is to make prototypes In the avor(s as detenined by laboratory Injection, After appropriate aging of the products (1-10 days) these are evaluated and checked against the previous laboratory injected cigarettes, In case of differences, adaptions have to be made to pilot plant/factory application methods (e