The main ingredients or tools to manufactured cigarettes are a tobacco blend, paper, PVA glue to bond the outer layer of paper together, and often also a cellulose acetate–based filter. While the assembly of cigarettes is straightforward, much focus is given to the creation of each of the components, in particular the tobacco blend, which may contain over 600 ingredients, many of them flavourants for the tobacco. A key ingredient that makes cigarettes more addictive is the inclusion of reconstituted tobacco, which has additives to make nicotine more volatile as the cigarette burns.

1. Filter made of 95% cellulose acetate. 2. Tipping paper to cover the filter. 3. Rolling paper to cover the tobacco. 4. Tobacco blend.
Paper
The paper for holding the tobacco blend may vary in porosity to allow ventilation of the burning ember or contain materials that control the burning rate of the cigarette and stability of the produced ash. The papers used in tipping the cigarette (forming the mouthpiece) and surrounding the filter stabilise the mouthpiece from saliva and moderate the burning of the cigarette as well as the delivery of smoke with the presence of one or two rows of small laser-drilled air holes.
According Professor Simon Chapman, who from public health at the University of Sydney, the burning agents in cigarette paper are responsible for fires and reducing them would be a simple and effective means of dramatically reducing the ignition propensity of cigarettes. Since 1980s Philipp Morris and RJ Reynolds developed fire-safe cigarettes but did not market them.
The burn rate of cigarette paper is regulated through the application of different forms of microcrystalline cellulose to the paper. Cigarette paper has been specially engineered by creating bands of different porosity to create “fire-safe” cigarettes. These cigarettes have a reduced idle burning speed which allows them to self-extinguish. This fire-safe paper is manufactured by mechanically altering the setting of the paper slurry.
Many U.S. states have passed or are considering fire-safe mandates. However New York was the first U.S. state to mandate that all cigarettes manufactured or sold within the state comply with a fire-safe standard. Canada has passed a similar nation-wide mandate based on the same standard.
According to a study made by European Union in 16 European countries, 11,000 fires were due to cigarettes between 2005 and 2007. They caused 520 deaths and 1600 people injured. Consequences, European union wishes to ban in 2011 cigarettes that are not fire-safe.
Tobacco blend
The process of blending, such as the blending of scotch and cognac will gives the end product a consistent taste from batches of tobacco grown in different areas of a country that may change in flavour profile from year to year due to different environmental conditions.
Modern cigarettes produced after the 1950s, although composed mainly of shredded tobacco leaf, use a significant quantity of tobacco processing by-products in the blend. Each cigarette’s tobacco blend is made mainly from the leaves of flue-cured brightleaf, burley tobacco, and oriental tobacco. These leaves are selected, processed, and aged prior to blending and filling. The processing of brightleaf and burley tobaccos for tobacco leaf “strips” produces several by-products such as leaf stems, tobacco dust, and tobacco leaf pieces (”small laminate”). To improve the economics of producing cigarettes, these by-products are processed separately into forms where they can then be possibly added back into the cigarette blend without an apparent or marked change in the cigarette’s quality. The most common tobacco by-products include:
* Blended leaf (BL) sheet: a thin, dry sheet cast from a paste made with tobacco dust collected from tobacco stemming, finely milled burley-leaf stem, and pectin.
* Reconstituted leaf (RL) sheet: a paper-like material made from recycled tobacco fines, tobacco stems and “class tobacco”, which consists of tobacco particles less than 30 mesh in size (~0.599 mm) that are collected at any stage of tobacco processing. RL is made by extracting the soluble chemicals in the tobacco by-products, processing the leftover tobacco fibres from the extraction into a paper, and then reapplying the extracted materials in concentrated form onto the paper in a fashion similar to what is done in paper sizing. At this stage ammonium additives are applied to make reconstituted tobacco an effective nicotine delivery system.
* Expanded (ES) or improved stems (IS): ES are rolled, flattened, and shredded leaf stems that are expanded by being soaked in water and rapidly heated. Improved stems follow the same process but are simply steamed after shredding. Both products are then dried. These two products look similar in appearance but are different in taste.
Whole tobacco can also be processed into a product called expanded tobacco. The tobacco is “puffed”, or expanded, by saturating it with supercritical carbon dioxide and heating the CO2 saturated tobacco to quickly evaporate the CO2. This quick change of physical state by the CO2 causes the tobacco to expand in a similar fashion as polystyrene foam. This is used to produce light cigarettes (”Lights”) by reducing the density of the tobacco and thus maintain the size of a cigarette while reducing the amount of tobacco used in each cigarette.
A recipe-specified combination of brightleaf, burley-leaf and oriental-leaf tobacco will be mixed with humectants such as propylene glycol or glycerol, as well as flavouring products and enhancers such as cocoa, licorice, tobacco extracts, and various sugars, which are known collectively as “casings”. The leaf tobacco will then be shredded, along with a specified amount of small laminate, expanded tobacco, BL, RL, ES and IS. A perfume-like flavour/fragrance, called the “topping” or “toppings”, which is most often formulated by flavor companies, will then be blended into the tobacco mixture to improve the consistency in flavour and taste of the cigarettes associated with a certain brand name. As well, they replace lost flavours due to the repeated wetting and drying used in processing the tobacco. Finally the tobacco mixture will be filled into cigarettes tubes and packaged.
In recent years, the manufacturers’ pursuit of maximum profits has led to the practice of using not just the leaves, but also recycled tobacco offal and the plant stem. The stem is first crushed and cut to resemble the leaf before being merged or blended into the cut leaf.
The process of making cigarette : From Seed to Pack
(more…)