Detailed Project Report on additive production for cigarette

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)