Emerald Quality Control

Quality can be defined as fulfilling specification or customer requirement, without any defect. A product is said to be high in quality if it functions as expected and is reliable. Quality control implies activities to ensure that produced items meet the highest possible quality standards. Most tools and techniques used to control quality are statistical techniques. Quality control techniques can be classified into basic, intermediate, and advanced. We are using the advanced level and the highest standards at all the stages of Emerald production.

Our laboratory has all the necessary prerequisites including international certifications for its accuracies like ISO 17025 :2005

Quality Assurance:


The various Quality Tests being carried out by The Quality Department & by Production Team during the production which are termed as On-Line & Off-Line inspections.


The facility where the Quality tests are being carried out is conforming to the International Standards and has been Certified by PMI in the year 2011-2012.


The Instruments being used for testing purpose are International Standards and are certified by PMI.


The Auditors carrying out various Quality Test in QA Lab are well trained & certified by PMI for conducting these tests.

 Primary Manufacturing Department:


The PMD is the most automated PMD and conforming to PMI latest standards of equipment's and process of 2013 which ensure 100% blend integrity & traceability.


The online Moisture meters TM 710 E are installed at critical stage to ascertain the moisture level of the blend. All the process parameters are monitored centrally on the SCADA system.


Each station has been equipped with HMI device for monitoring & controlling.


Online Temp sensors are available at required stages with recordings in SCADA systems.


Extensive calibration process and reviews are available.

SMD: (Cigarette Making and Packing)


The machine (GD-121, X-600) which we are using for production of EMERALD Cigarette is the latest generation machine with best in class online Cigarette Inspection Device (loose ends, PD & ventilation) Quality check sensors.


Cut tobacco stores and SMD is done under RH and Temp controlled as per PMI norms.






Our Smoking Machine


Our Smoking machines RM200, RM200A and SM450 are used in the R&D. R & D Analytical laboratory analyses cigarettes by 'smoking' according to ISO 4387:2000.

Determine The Nicotine Level


Nicotine content in smoke condensate is estimated as per ISO 10315:2013 and analyzed using Agilent 7890B with FID detector.

Measuring The Humidity


Water content in smoke condensate is estimated as per ISO 10362-1:1999 (Amd1-2011) and analyzed using Agilent 7890A with TCD detector.

The Moisture Measurement


Moisture in tobacco is estimated as per PMI 274 by drying in Freas type oven at 100°C for 180 minutes in R&D & in Binder type oven at 103°C for 100 minutes in QA.


An instrument measures the weight, diameter, ventilation and the pressure drop in the cigarettes and in the filters.


Diameter (or circumference) is measured as per ISO 2971:1998.


Ventilation is measured as per ISO 9512:2002.


Pressure drop is measured as per ISO 6565:2011.



Tobacco Quality Control


Total Alkaloids in tobacco is analyzed as per ISO 15152:2003 (Amd1-2012).


Total Reducing Sugars by ISO 15154:2003 (Amd1-2012).


Ammonia by Skalar method 155.922 (2004).


Nitrates by Coresta Method N°36.

Production Materials Quality Control


1- The Cigarette Pack Seal Testing

Pack Seal integrity is inspected during visual inspection following PMI method.


2- The Cigarette Paper Permeability Measurement

Our machine measures the permeability of the paper used in the various processes of the cigarette fabrication. Utilizing both vacuum and pressure methods, the machine is a comprehensive unit capable of measuring the entire portfolio of tobacco papers across the required measurement range.


Cigarette Paper Permeability is analyzed as per ISO 2965:1997 and reported in Coresta units.


3- The Cigarette and Filter Rods Hardness Measurement

Cigarette Firmness measured with PMI Q712 method and Filter rod hardness is measured as per ISO 2971:1998 and reported in mm.

Aroma Preparation Quality Control



The flavor preparation is done in flavoring kitchen which is ATEX (EU norms) certified. We have raw chemical storage tanks and mobile tanks with stirrers for mixing for flavor preparation and during application. The mobile tank is then taken near flavor cylinder (all motors ATEX –EU norms certified) and through electronic codes blend and flavor integrity is ensured along with traceability. This process does not involve heating.



In a special area called Casing kitchen, we have raw material storage tanks and casing preparation tanks. In casing "preparation and application" tank, specific quantities of formula ingredients are added to the tobacco which is blend specific through PLC controlled pumping systems and subsequently mixed and heated up to 57 Deg C for 10 mins in standby mode and during batch processing, it is maintained at 57 deg C which lasts for 35 mins. Casing "preparation and application" tank is directly connected to DCCC Machine (Direct Conditioning & Casing Cylinder) with Electronic coding to ensure blend and casing integrity along with traceability.

Finished Goods:


Before and after stuffing, container undergoes an inspection process, photographed & post conformance, sealing of container is done.

All master cases are Sr. No. Controlled which appears on invoice and packing list of export shipment for Local Excise Regulations compliance & also for traceability purpose.