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American Blended Cigarettes (ABC) Technology
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
FAWKY ABDALLAH COMPANY, INC.
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
A Presentation by
Fawky Abdallah,
Ph.D.
at An Open Meeting on
The Relative Risk of Non-Tobacco Ingredients Added to Cigarettes
Organized by
Life Science Research Office
Washington, DC, November 5, 2003 FAWKY ABDALLAH COMPANY, INC.
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
I.
DEFINITIONS II. MANUFACTURING OPERATIONS III. BLENDING IV. PROCESSING V. RECENT DEVELOPMENTS VI. RECOMMENDATIONS
FAWKY ABDALLAH COMPANY, INC.
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
I. DEFINITIONS
A. Cigarette Smoke A. Smoke Chemistry A. Smoke Yield A. Smoking Qualities A. Additives
FAWKY ABDALLAH COMPANY, INC.
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
A. Cigarette Smoke
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The cigarette is technically a smoke-delivery system.
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Smoke Formation The burning cone where the processes of pyrolysis degradation
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take place The thermal gradient zone ahead of the burning cone where processes of distillation, volatilization, sublimation, cellular eruption, and chemical interactions take place
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Nature of Smoke As MSS travels in the tobacco column, it is subjected to air dilution through the cigarette paper, tipping, perforation and ventilation, where condensation and re-volatilization take place. Cigarette smoke is a dynamic system as evidenced by the different physical, chemical and sensory properties of fresh smoke versus stale smoke or smoke condensate.
FAWKY ABDALLAH COMPANY, INC.
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
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B. Smoke Chemistry
Research and analytical chemists identify the thousands of components in total particulate matter (TPM), commonly called Tar, and in the gaseous phase of cigarette smoke. Blenders work on the foundation blend and develop the extenders, casing and flavorings that complement the blend in order to have a total blend cut rag with the target nicotine and sugars while maintaining the desired smoking qualities. Process engineers determine the processing parameters and cigarette design configuration that are required to produce the cigarettes with the target tar and nicotine deliveries and acceptable smoking qualities. FAWKY ABDALLAH COMPANY, INC.
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
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C. Smoke Yield
Toxicologists, biologists and workers on smoking and health are concerned not only with deliveries of tar and nicotine in the cigarette MSS but also its content of specific harmful compounds, such as nitrosamines, benzo-a-pyrine, phenols and carbon monoxide.
Studies on smoke yield investigate the carcinogenic, co carcinogenic, antagonistic and other risks of the smoke compounds to test animals in an effort to explore health risks to humans (smokers). FAWKY ABDALLAH COMPANY, INC.
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
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D. Smoking Qualities
Product developers study the physical and chemical properties of the MSS required for the target cigarettes.
Sensory analysts refer to smoking qualities as the sensory properties of the “fresh” MSS as determined by flavor (taste, smell and feel), aroma, mildness, after-taste, impact, burning qualities, etc. Sensory analysts train and use smoking panels, as a measuring device, to evaluate the smoking qualities of the test cigarettes. Marketing specialists conduct consumer tests using focus groups and market surveys to determine overall acceptability of an ABC product in terms of smoking qualities, price, brand identity, etc.
FAWKY ABDALLAH COMPANY, INC.
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
E. Additives
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Casings, flavorings, humectants and any other non-tobacco ingredients added during cigarette manufacturing are collectively called additives.
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Additives cover anything added to tobacco during processing other than water and to the cigarette paper, filter and tipping during making.
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Additives should meet the regulations required by one or more pertinent authorities, such as FDA, IFT, ASTM, FEMA, WHO’s JECFA and CoE.
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Since the actual product consumed is the MSS and not the cigarette per se, the acceptability of certain ingredients for use in food does not necessarily mean approval for use in smoking tobacco products, such as cigarettes. FAWKY ABDALLAH COMPANY, INC.
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
II. MANUFACTURING OPERATIONS
A. Primary Operation
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Blending and Processing
B. Secondary Operation
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Cigarette Making and Packing FAWKY ABDALLAH COMPANY, INC.
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
A. Primary Operation
Foundation Blend Flue-cured, burley and oriental Extenders reconstituted sheet, expanded cut tobacco and cut-rolled expanded stems Additives casings, flavorings and humectants Processing six main stages FAWKY ABDALLAH COMPANY, INC.
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
B. Secondary Operation
Cigarette Making Tobacco column: moisture content, weight, density, firmness, filling value, pressure drop, etc. Cigarette configuration: paper, porosity, filter, tipping, ventilation, perforation, etc.
Cigarette Packing Package design and packaging materials FAWKY ABDALLAH COMPANY, INC.
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
III. BLENDING
A. Why Blending?
B. Basic Principles C. Deciding Factors
FAWKY ABDALLAH COMPANY, INC.
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
A. Why Blending?
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No perfect grade Inherent variations among tobacco types, origins, crops and stalk positions Incompatibility between elements of tobacco quality
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Principle Each grade has specific traits in terms of quality and value.
The quality of a grade is the degree it contributes to the blend.
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Know-how Good blending is achieved when the quality of the blend is more desirable than the sum of the qualities of the grades therein.
FAWKY ABDALLAH COMPANY, INC.
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
B. Basic Principles
1. Balance 2. Categories 3. Criteria 4. Philosophy Physical, chemical and sensory properties of component grades FF: Full Flavor Grades, MF: Medium Flavor Grades and FG: Filler Grades No set of criteria fits all types and grades. Different tobacco criteria for each type and within type by origin, crop year and stalk position. Different processing parameters for different blend components, especially burley casing and toasting Optimization of quality criteria with cost availability and continuity FAWKY ABDALLAH COMPANY, INC.
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
C. Deciding Factors in Blending
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2.
3.
4.
5.
Blend chemistry Nicotine and sugars Physical properties Filling value and processing ability Smoke chemistry Tar and nicotine deliveries Smoking qualities Sensory properties and burning qualities Economics Cost, availability and continuity of leaf tobacco and extenders FAWKY ABDALLAH COMPANY, INC.
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
IV. PROCESSING
A. Primary Processing B. Why Casings?
C. Why Flavorings? D. Role of Additives
FAWKY ABDALLAH COMPANY, INC.
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
A. Primary Processing
A typical ABC primary operation consists of six main stages: 1. Burley Casing & Toasting (Heat Treatment) 2. Total Blend Casing 3. Expanded Cut Tobacco (ECT) 4. Cut-Rolled Expanded Stems (CRES) 5. Total Blend Cutting, Drying, Cooling 6. Flavorings (Top Dressing) Option: Top Casing may be applied before cutting.
FAWKY ABDALLAH COMPANY, INC.
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
B. Why Casings?
Casing is an integral part of processing any ABC product. Ingredients Sugars, licorice, cocoa, fruit concentrates, humectants and water Benefits 1. Sugars improve the overall sensory quality, esp. smoke flavor.
2. Licorice, cocoa and fruit concentrates contribute to basic taste. 3. Humectants improve tobacco processing ability and increase its moisture holding capacity, thus extending the product’s shelf life.
4. The casing’s solids act as a cost-reducer, by replacing tobacco in the cigarette rod while maintaining the same puff count. FAWKY ABDALLAH COMPANY, INC.
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
C. Why Flavorings?
Flavoring is an integral part of processing any ABC product.
Ingredients Aroma chemicals, essential oils, natural and/or synthetic extracts and commercial flavorings Benefits 1. Ameliorates off taste and negative flavor attributes usually associated with tobacco smoke 2. Generates a balanced smoke flavor matrix 3. Imparts “signature” pack aroma and smoke flavor that are unique to each particular ABC product Formula There is no formula or ratio that fits all ABC products.
Each ABC product requires a formula and ratio that complement the particular blend. FAWKY ABDALLAH COMPANY, INC.
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
The Use of Additives
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Additives should be used with care in order to complement, not overpower, the basic tobacco characters, and positively contribute to processing ability, smoking qualities and safety.
The increase in demand to produce “safer” cigarettes with lower yield and acceptable smoking qualities led to efforts to develop new additives and application techniques. Additives can be used to enhance the signature flavor matrix and pack aroma of the “safer” cigarettes with reduced yield. Additives’ Golden Rule
Use a minimum number of components at lowest possible levels that can provide maximum positive effects on physical properties, smoking qualities and overall smoke chemistry in terms of safety, while preserving the ABC product integrity.
FAWKY ABDALLAH COMPANY, INC.
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
V. RECENT DEVELOPMENTS
A. New Target and New Direction B. Sensory Testing C.
What “Tar”? D. Acceptability and Safety E. Review of Literature
FAWKY ABDALLAH COMPANY, INC.
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
A. New Target & New Direction
Target Development of “safer” cigarettes with MSS that has: - Lower-tar and nicotine deliveries - Reduced yield of harmful compounds - Acceptable smoking qualities Direction Work on breeding and cultural practices Make blend changes in the grades of each sub-blend Adjust extenders: recon, ECT and CRES Review additives: casings, flavorings and humectants Modify cigarette design: Tobacco rod’s weight, filling value, density, etc., and Cigarette’s paper, filter, tipping, plug wrapper, ventilation, perforation, etc.
FAWKY ABDALLAH COMPANY, INC.
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
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B. Sensory Testing
There are many studies on the chemistry and biological activity of cigarette smoke; however, the most advanced chemical devices cannot “sense” the qualitative aspect of MSS and its sensory properties as perceived by the smoker.
Recent efforts to develop “safer” ABC products with lower yield and acceptable smoking qualities have revitalized the important role of sensory testing.
Adequate smoking panels should be used as a measuring device parallel to the chemical and physical testing devices now being used in product development.
FAWKY ABDALLAH COMPANY, INC.
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
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C. What “Tar”?
The total particulate matter (TPM) of the cigarette MSS is commonly called “tar”, a term that is oftentimes misleading. The tar delivery per se does not necessarily reflect specific sensory properties or indicate a certain safety factor. Many ABC brands have similar tar delivery but differ greatly in smoking qualities as reflected by acceptability in the market place. This presumably reflects qualitative differences between tars that may also reflect differences in the degree of safety, in terms of the level of harmful compounds such as benzo-a pyrene, nitrosamines, phenols, CO, etc. FAWKY ABDALLAH COMPANY, INC.
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
D. Acceptability and Safety
Besides acceptability in terms of smoking qualities, the safety of MSS in terms of deliveries of tar, nicotine and other harmful compounds should also be considered. Complexity Acceptable smoking qualities are oftentimes incompatible with low tar and nicotine deliveries in the MSS.
Solution Adequate application of technology and know-how through product development programs in two major areas:
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Blending and processing
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Cigarette design configuration FAWKY ABDALLAH COMPANY, INC.
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
Role of Blending and Processing
Blend. Replace some of the high-yield FF grades with lower yield MF grades while maintaining acceptable smoking qualities. Extenders. Increase the inclusion of recon in order to reduce the tar delivery while preserving the smoking qualities. Also, increase the ratio of expanded cut tobacco and/or CRES to reduce tar.
Additives. Adequately adjust the formula and application rate of the casings, flavorings and humectants to enhance the flavor attributes of the ABC product with reduced yield. Processing. Develop techniques that can improve processing ability and increase filling value and moisture-holding capacity of the cut rag with reduced tar. FAWKY ABDALLAH COMPANY, INC.
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
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Role of Cigarette Design
Although blending and processing play an important role in developing lower-yield cigarettes with acceptable smoking qualities, cigarette design configuration plays an equally important role.
For many years the reduction of tar and nicotine in MSS was handled mainly through cigarette design, using advances in paper porosity, filter, tipping, ventilation, perforation, etc. This led to gradually reducing the average deliveries in MSS of all cigarettes sold in the U.S. by about one half over the last 40 to 50 years. Further reduction should be undertaken through coordination between blending and processing and cigarette design; otherwise, the resulting lower-yield cigarettes will have undesirable smoking qualities. FAWKY ABDALLAH COMPANY, INC.
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
E. Review of Literature
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Following are the main recent publications and on-going studies on the evaluation of the health effects and relative risks of non-tobacco ingredients added to cigarettes during manufacturing: JTI’s Paschke et al 50-year review 1952-2002 PM’s Carmines et al RJR’s Rodgman et al 4 parts 2 parts 2002 2002 BAT’s Baker el al LSRO’s independent on-going on-going 2003 2003 FAWKY ABDALLAH COMPANY, INC.
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
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Results of Studies
To date, almost all studies indicate that the commercially used ingredients do not change the toxicity of smoke as measured in specific assays. The added ingredients have no effect on the levels of most smoke constituents that are known to be relevant to smoking related diseases.
Neither flavoring nor casing and humectant ingredients added during today’s cigarette manufacturing in the USA increase the toxicity of cigarette smoke. FAWKY ABDALLAH COMPANY, INC.
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
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Controversies
A large number of studies reveal scientific controversies about the risks of cigarette ingredients.
The controversies are due to the diversity of test materials, test conditions and test procedures among investigators.
The complexity of studying the role of ingredients in the
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health risks of cigarette smoking is also due to the lack of: Standardized procedures to test “fresh” smoke Ethically- accepted methodologies to employ human subjects (smokers) to participate in the required tests FAWKY ABDALLAH COMPANY, INC.
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
VI. RECOMMENDATIONS
A.
Concept of “Safer” Cigarettes B. Suggested Protocol C. Parallel Programs D. Smoking Behavior
FAWKY ABDALLAH COMPANY, INC.
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
• • • •
A. Concept of “Safer” Cigarettes
Recent research and product development studies indicate that it may be possible to make “safer” cigarettes with reduced yield of tar, nicotine and harmful compounds, but the outcome most probably will be of undesirable smoking qualities.
The current challenge is to develop the “safer” cigarettes with reduced yield while maintaining acceptable smoking qualities.
Developing a “safer” cigarette with inferior smoking qualities does not contribute to safety if no one smokes it.
It is the obligation of the cigarette industry along with pertinent state and national institutions to join efforts in order to meet this challenge. FAWKY ABDALLAH COMPANY, INC.
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
B. Suggested Protocol
To support the ongoing efforts to develop “safer” cigarettes with acceptable smoking qualities, the health effects and relative risks of additives should be investigated. I suggest that this should be done through an aggressive and progressive multi-disciplinary working arrangement, or Protocol, reflecting the joint efforts of the cigarette industry, covering:
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Blending & Processing
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Cigarette Manufacturing
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Product Development Smoke Chemistry
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Biology and Toxicology Sensory Testing Market Research Data Processing FAWKY ABDALLAH COMPANY, INC.
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
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C. Parallel Programs
The use of additives, as a tool in the development of “safer” cigarettes with acceptable smoking qualities, represents a serious challenge.
This challenge should be addressed through coordinated research studies by all concerned, instead of separate and unrelated studies that oftentimes lead to contradictory results and unnecessary recriminations.
I suggest that, along with the industry’s collective effort, or Protocol, similar efforts or Parallel Programs, should be carried out by the pertinent state and national institutions. FAWKY ABDALLAH COMPANY, INC.
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
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D. Smoking Behavior
Besides the possible health risks of additives per se, the safety of the lower-yield cigarettes depends on how and to what extent the smokers actually smoke the cigarettes.
Studies on smoking behavior play an important role in the ongoing effort to develop “safer” cigarettes with acceptable smoking qualities. The behavioral aspects and sensory responses of the prospective smokers will determine the degree of safety that each reduced-yield cigarette is actually providing.
FAWKY ABDALLAH COMPANY, INC.
A Suggested Protocol for Studies of Risks of Additives Used in the Production of Cigarettes
Thanks for your attention.
I will now entertain your questions or comments.
Fawky Abdallah
FAWKY ABDALLAH COMPANY, INC.