JAUBTM 1 1 September 1989
(SECRET)
EXTRUSION
The R&D Centre extrusion programme has been running since 1986, although a small
amount of exploratory work was undertaken in 1984. It is based on the APV-Baker
MPF 50:15 food extruder adapted to process tobacco or other organic or inorganic
materials.
The programme has concentrated on the evolution and development of a reconstituted
tobacco material derived from factory o!!--J (Project DEER), although experimental work
has demonstrated- that a wide range of other materials, some combustible, can be
produced e.g. for AIRBUS, for filters etc.
DEER has a formulation based mainly on tobacco waste and starch with small amounts
of cellulosic binders which allows the extrusion of a thin foamed sheet of extrudate.
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This sheet is shredded to produce a cut product resenlWM tobacco for add-back at
theendoftheprimaryprocess. Theshreddedmaterialisinherenflyflexibleandresistant
to dusting which aids its performance during cigarette manufacturing, avoiding
degradation.
Extensive testing of the product and process has revealed that little, if any, chemical
change occurs to the tobacco in the extruder. Nicotine is not lost, because operating
temperatures are low. In cigarettes there is little difference in smoke chemistry between
cigarettes with and without DEER inclusion. This was reflected in biological testing
both intemally and at Hazleton laboratories. AGP approval for use of DEER at up to
20% inclusion has been given. There is no loss of firmness in cigarettes when DEER
is substituted for whole blend up lo 150/./17%. Ends fall-out, static burn rate and coal
shape and retention are unaffected. Repeated panel testing of products containing
DEER from same style offal have not revealed any detectable differences when
compared with regular brands.
Worldwide patent coverage has been sought for DEER.
The DEER core-plant has a capacity of 150 Kg/hr. depending on offal density and costs
in the region of E200,000. Larger scale could be used if needed. The material recipe.
fixed for AGP clearance, has proven robust. Only one of twenty (20) offals evaluated
has forced a slight revision. DEER cost in the U.K. is 38p/Kg or 35% of SRT cost.
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BATCo document for Province of British Columbia 16 April 1999

Tho first production plant has been commissioned in Montreal with full transfer of the
know-how. Souza Cruz and Singapore Tobacco have plant on order, with Kenya,
BAT(UK&E) and others moving swiftly to that position.
Where tobacco legislation exists, steps are being taken to ensure DEER ingredients
are on approved lists. A recent submission to the ISCSH was made in the U.K.
Derivatives of DEER are being evolved under FUTE (the addition of casings and
flavours) and AMTECH (effecting Maillard reactions), the latter currently aimed to
produce a match for RCB in 'Belmont' (Venezuela).
One of the highest priority new projects in R&DC is EPCOT, which seeks to produce
a one-piece foamed extruded cigarette in which the loam structure is substantially
open-called and can be controlled to give appropriate mechanics and physical qualifies.
In this new technology unprocessed tobacco is ground then blended, mixed with starch
andbindersandfeddirectlytotheextruder. Followingextrusionthroughasmallcircular
dieandexpansion,therodiscooled,sizedandfeddirectlytoacigarettemakingmachine
garniture for enrobing in paper and tipping it needed.
Effectively the whole of primary processing is eliminated and secondary machines much
simplified. The financial implications are enormous. PP&D have already estimated
that such a plant producing 2.2 billion cigarettes per annum could allow capital savings
of E5.5 million. At the same time there would be a great reduction in manpower need,
the ation of tobacco waste, significant reductions in the need for space and large
saving in buildings and land requirement.
Longerterm development of a successful EPCOT product could be expected to include
the incorporation of specific materials to reduce sidestream, Ames activity etc. or
significantly alter the burning characteristics of products to meet future consumer or
legislative needs.
J.A. LUKE
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BATCo document for Province of British Columbia 16 April 1999