ADDITIVE PRODUCTION FOR CIGARETTE
[CODE NO.3698]
Tobacco products, most commonly cigarettes, have come to include more and more additives in recent decades. They include agents to retain moisture and preservatives, as well as a large range of flavourings and other chemicals which modify the properties of tobacco or the experience of smoking.
Some of these additives may make addiction to tobacco as a source of nicotine more likely. They may affect addictiveness of the product or simply make smoking more attractive. The number of additives is so large, and the chemical mixtures produced by cigarettes so complex, that measuring effects of individual additives is difficult, and expensive.
Cigarettes are a small roll of porous paper containing a rod of chopped up tobacco leaf. Cigarettes are designed so that the tobacco can be smoked, by lighting the cigarette and breathing in the smoke. At the mouth end of the cigarette there is a second layer of porous paper (called tipping paper) and a filter. The tipping paper is designed to allow fresh air to infiltrate when the smoker inhales. This fresh air reduces the harshness of the smoke. The filter cools the smoke and reduces the flow of smoke out of the cigarette. Cigarettes also contain additives such as sugars and flavourings which are used to increase shelf life, control the rate at which the cigarette burns and control the delivery of the chemicals.
COST ESTIMATION
Plant Capacity 80 MT/Day
Land & Building (5000 sq.mt.) Rs. 3.05 Cr
Plant & Machinery Rs. 52 Lac
Working Capital for 1 Month Rs. 29 Lac
Total Capital Investment Rs. 4.43 Cr
Rate of Return 17%
Break Even Point 68%
INTRODUCTION
CIGARETTES VARY IN STRENGTH, TASTE AND INTENSITY DEPENDING UPON:
MENTHOL
MAIN TOBACCO PRODUCTS
HOW CIGARETTES MADE
CIGARETTE DESIGN
A. RAW MATERIALS
B. TOBACCO TYPES
1. FLUE CURED TOBACCO
2. BURLEY TOBACCO
3. ORIENTAL TOBACCO
C. COMBUSTION BY-PRODUCTS
1. FREE RADICALS
D. OVERVIEW OF MANUFACTURING
E. RECONSTITUTED TOBACCO (RECON)
RAW MATERIAL COMPONENTS AND COMPOSITION OF RECON
HOW IS PAPER RECON MADE?
TYPE I
TYPE II
3. BAND CAST RECONSTITUTED TOBACCO (DARK RECON)
CIGARETTE FILTERS
1. FILTERS:
FILTERS GENERALLY HAVE THE FOLLOWING COMPONENTS:
2. TOBACCO AND NICOTINE IN CIGARETTES:
3. ADDITIVES TO TOBACCO:
4. CIGARETTE WRAPPER AND GLUE
CIGARETTE SMOKE
NICOTINE
CARBON MONOXIDE
TAR
CIGARETTE ADDITIVES
1. PROCESSING AIDS
2. COMBUSTION AIDS
3. HUMECTANTS
4. NICOTINE CONTROLLERS
FLAVOURS
FLAVOURED CIGARETTES
AMOUNTS OF NICOTINE AND TOBACCO AS WELL AS PERCENTAGE OF NICOTINE CONTENT IN EACH CIGARETTE IN DOMESTIC BRANDS*
ADDITIVES INCLUDE: GLYCEROL, PROPYLENE GLYCOL AND SORBITOL.
TASTE AND EXPERIENCE OF THE SMOKE
HARSHNESS
SMOOTHNESS
LEVULINIC ACID AND LEVULINATES
MENTHOL
COOLER AND MILDER SMOKE
THE LIST OF 599 ADDITIVES IN CIGARETTES
APPLICATION OF ADDITIVES
SUGAR AMPLIFIES YOUR ADDICTION.
COCOA LETS YOU INHALE MORE DEEPLY.
MENTHOL REDUCES THE SENSATION OF IRRITATION AND PAIN.
AMMONIUM RELEASES MORE NICOTINE.
LEVULINIC ACID SMOOTHES TOBACCO TASTE.
ADDITIVES THAT CAUSE LESS IRRITATION:
ADDITIVES THAT MAKE SMOKE LESS VISIBLE:
MARKET SURVEY
WHO GLOBAL REPORT ON TRENDS IN TOBACCO SMOKING 2000-2025
ESTIMATES OF CURRENT TOBACCO USE AMONG YOUTH
ELECTRONIC CIGARETTES (E-CIGARETTES)
TOBACCO PRODUCT USE AMONG HIGH SCHOOL STUDENTS – 2018
CIGARETTES
CIGARS
SMOKELESS TOBACCO
HOOKAH
ALL TOBACCO PRODUCT USE
INDUSTRY INSIGHTS
TYPE INSIGHTS
REGIONAL INSIGHTS
TOBACCO MARKET SHARE INSIGHTS
MAJOR PLAYERS OF GLOBAL TOBACCO ADDITIVES MARKET:
GLOBAL TOBACCO ADDITIVES MARKET BY PRODUCT TYPE :
GLOBAL TOBACCO ADDITIVES MARKET BY PRODUCT APPLICATION:
MANUFACTURING PROCESS
MENTHA CRYSTAL MANUFACTURING PROCESS:-
PROCESS OF MANUFACTURE
PROPYLENE GLYCOL MANUFACTURING PROCESS:-
MANUFACTURE
RAW MATERIAL BASIS -1000KG PROPYLENE GLYCOL (97% YIELD)
REACTION: CATALYST SILVER
MANUFACTURE PROCESS
ACETALDEHYDE MANUFACTURING PROCESS:-
MANUFACTURE PROCESS
UNIT 100
UNIT 200
THE FOLLOWING REACTIONS OCCUR DURING THE DEHYDROGENATION OF ETHANOL:
THE CONVERSION OF ETHANOL IS ASSUMED TO BE 60.8%.
EQUIPMENT SUMMARY
QUALITY CONTROL AND STANDARDS
MENTHOL CRYSTALS
ACETYLDEHYDE FOOD GRADE:-
PROPYLENE ALOCOHOL :- IS 13702 : 1993
MACHINERY MANUFACTURER
MENTHOL CRYSTAL:-
CHILLING PLANT
CENTRIFUGE HEAVY DUTY
S.S. REACTION VESSEL WITH STIRRER
VACUUM FILTER
S.S TRAY FOR STORAGE
PROPYLENE GLYCOL
REACTOR (2-3KL)
MULTIPLE EFFECT EVAPORATORS
DRYING TOWER
VACUUM DISTILLATION UNIT
ACETALDEHYDE REACTOR PREHEATER
HEAT EXCHANGER
FIRED HEATER
FLASH VESSEL
RAW MATERIAL SUPPLIER
PROPYLENE OXIDE
ETHANOL
RAW MATERIAL PHOTOGRTAPHS
MINT OIL
PROPYLENE OXIDE
ETHANOL
MACHINERY PHOTOGRAPHS
MENTHOL CRYSTAL:-
CHILLING PLANT
CENTRIFUGE HEAVY DUTY
S.S. REACTION VESSEL WITH STIRRER
VACUUM FILTER
S.S TRAY FOR STORAGE
PROPYLENE GLYCOL
REACTOR
MULTIPLE EFFECT EVAPORATORS
DRYING TOWER
VACUUM DISTILLATION UNIT
ACETALDEHYDE
REACTOR PREHEATER
HEAT EXCHANGER
CONDENSER
REBOILER
FIRED HEATER
BOILER FEED WATER PUMP
REFLUX PUMP
ABSORBER
DISTILLATION COLUMN
FLASH VESSEL
REFLUX VESSEL
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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