494 



REPORT OF THE REVIEW OF THE 



PHILIP MORRIS, U.S.A. 



MANUFACTURING FACILITIES 



AS SUBMITTED TO 



SHERWIN GARDNER 



I. FACILITIES 



A. Introduction 



Based on prospective observation by the reviewing team, it is evident Philip Morris. U.S. A 

 has developed several processes that utilize all of the parts of the purchased leaf tobacco used 

 in the manufacture of cigarettes. Reconstituted tobaccos, described later, have become 

 significant components, along with leaf tobacco, in the filling of cigarettes. The in-process 

 and finished product testing controlled for flavor levels, texture, and moisture content; the 

 nicotine level of the tobacco is neither monitored nor controlled via additives. 



Cigarettes are made by blending various grades and types of both domestic and foreign 

 tobaccos and reconstituted tobacco products of natural origin. Three types of natural tobaccos 

 are purchased for cigarette production: Bright tobacco, which has been flu-cured: Burley 

 tobacco, tobacco thai has been air-cured; and sun-cured tobacco, or Oriental tobacco. The 

 blends are accented with an assortment of fla\ors and humectants at several stages of 

 production before the tobaccos are formed into the commercial product, cigarettes. 



The raw tobacco leaves chosen for production undergo a procedure which removes the stem 

 and veins from the body of the leaf (threshing). Bales of Oriental tobacco are not threshed, 

 but are aged until production. The remaining portion of the leaf (lamina) is stored in round 

 barrels (hogsheads) until direct transfer to the cigarette manufacturing facility after aging. 

 The stems, dust, and small leaf parts (below 1/4 inch) are transferred to facilities responsible 

 for manufacturing the two types of reconstituted tobacco used by Philip Morris. U.S.A.. 

 blended leaf and reconstituted leaf tobacco. The products from each of these facilities are 

 blended with leaf tobacco for the production of cigarettes. 



Flavoring is a key element of the cigarette process. Philip Morris, U.S.A. adds numerous 

 flavors during the reconstituted leaf process, blended leaf process, and final blending process 

 Many of the flavors are mixed at the facility of use, while other formulations are blended by 

 the Philip Morris Flavor Center. Flavors are added as aqueous mixtxires during the 

 manufacture of the blended leaf and reconstituted leaf tobaccos, during the preparation of the 

 leaf tobaccos, or "casing" process, and in a denatured alcohol spray on the final blend. 



As shown in a flow diagram on the following page, all of these procedures are key elements 

 of the final manufacture of cigarettes. Threshing, which is performed by a contractor, was 

 not reviewed or inspected. Threshing is a purely physical process in which no additives are 

 used. The findings during the review of the facilities responsible for blended leaf, 

 reconstituted leaf, flavoring, and cigarette manufacturing are discussed further. 



