Innovative flavor release systems in heat-not-burn devices and e-cigarettes

The choice of flavors is one of the main reasons why Heat-Not-Burn (HNB) devices and e-cigarettes are so popular. However, maintaining a consistent aroma and flavor in these smokables is difficult. Existing heating systems are prone to carbon accumulation, which releases an unpleasant burnt taste. Furthermore, adding flavors to prerolled smokables is not user-friendly, limiting the user’s choices.

Tobacco companies and researchers have created several cost-effective methods to address these flavor release issues. Chinese tobacco corporations have designed a newer aroma release system for heat-not-burn (HNB) devices that greatly improves the taste. Aidemar Group has simplified the flavor-release mechanism for pre-rolled cones, simplifying manufacturing and ease of use. In addition, Nicogen has created a tobacco formulation that mimics traditional cigarettes with a thicker sensation and improved exhalation experience in vapes.

This report discusses more such innovations in flavor release in HNBs and e-cigarettes. To get early access to a comprehensive report on tobacco trends in 2025, please fill out the form below.

Flavor Release in HNB (Heat-Not-Burn) Devices

Innovations in flavor release are related to control systems and design for consistent airflow. These are required to meet consumer expectations for high-quality HNB products.

China National Tobacco Corporation developed a Modulated Aroma Release Mechanism for HNB devices.

In traditional cigarettes, a blend of leaf formula derives the aroma, which can be further enriched with added flavors to maintain consistency. However, in heated and electronic cigarettes, the stability of aroma release during use is a challenge. This directly impacts the quality and consistency of the aerosol product’s taste.

To address these aroma issues, China National Tobacco Corporation, in collaboration with Zhengzhou Tobacco Research Institute and Yunnan China Tobacco Industry, developed a new aroma release system. This solution includes an aerosol-generating device and a fragrance carrier to modulate the release of aroma substances. Its design ensures that the release of aroma substances is stable and consistent, significantly improving the taste and quality of aerosol products.

Tobacco Research Institutes achieved consistent aroma diffusion in HNB devices using a cigarette cup.

In Heat-Not-Burn (HNB) devices using an oxygen-depleted heating process, the lack of airflow through the tobacco can confine smoke in the smoking section. This results in inconsistent diffusion rates of aroma-causing substances compared to conventional heated cigarettes. This affects the aerosol generation and extraction mechanism, leading to uneven and inconsistent smoke, which diminishes the overall user experience.

To address the problem of inconsistent aroma diffusion, China National Tobacco Corporation, Zhengzhou Tobacco Research Institute, and Henan China Tobacco Industrial Co., Ltd. have collaboratively developed a novel aerosol generation system.

This system includes an aerosol-generating device with a cigarette cup, a smoking section, and a functional section arranged coaxially. The functional section includes a cavity with a side wall through holes, which creates an airflow channel from the outside to the inside, helping to enhance smoke movement.

Flavor Release in Pre-rolled Cones

A major trend in pre-rolled cones is incorporating flavor-releasing mechanisms, like “click balls,” within smokable inserts. Companies are developing cost-effective insert systems that securely house these flavor mechanisms, simplifying manufacturing and ensuring proper placement and functionality. 

Another trend is enhanced filters made from natural materials with integrated flavor capsules. These filters provide a safer, eco-friendly alternative to synthetic fibers and offer customizable flavor options, improving user satisfaction.

Aidemar Group designed a cost-effective flavor-releasing mechanism in a smokable insert.

Aidemar Group has a cost-effective insert system for mouthpieces in smokable items designed to house at least one flavor-releasing mechanism securely. The system consists of a long rolled material with open ends and an inner volume. Inside the rolled material, a partition creates at least two elongated compartments.

One of the compartments contains a small sphere filled with flavor material, known as a “click ball,” which is held in place by friction. This design simplifies manufacturing, reduces labor costs, and ensures proper placement and securement of the flavor-releasing mechanism within the smokable insert.

New insert mouthpiece that secures a flavoring mechanism

If a smokable or empty cone does not include a flavoring mechanism, users must manually hollow out a space within the insert to add one. This process often results in the flavoring mechanisms falling out and not working correctly. Furthermore, adding a flavoring mechanism to an existing smokable can lead to its contents spilling, complicating the user experience and reducing product satisfaction.

Aidemar Group has solved this consumer problem with an innovative insert system for smokable items. The system includes rolled material that forms an elongated section with openings on either end. 

This design accommodates various shapes, supporting both conical and cylindrical options. It enhances the user’s smoking experience by simplifying the addition of flavor mechanisms without the risk of spillage.

Good Tree International made a filter from natural materials instead of synthetic fibers.

Hand-rolled smokables often use synthetic filters, like cellulose acetate and rayon, which can be harmful when burned or inhaled. Adding flavors to hand-rolled smokables is also difficult, limiting the smokers’ customization options.

Good Tree International has created a new filter for hand-rolled smoking products that can hold flavoring. The filter has a body with an outer surface and an internal cavity. Inside the cavity, there’s a filter element with multiple channels. A flavor capsule is placed within one of these channels between the outer surface and the filter element.

(Image: Source)

This filter element can also be made from natural materials such as corn husk, Cordia, manjack, palm, rice paper, hemp paper, wood pulp, bleached paper, and unbleached paper, ensuring a safer and more eco-friendly alternative to synthetic fibers. The capsule releases the flavoring agent when crushed, providing a customizable smoking experience.

Flavor Enhancement in E-cigarettes

Key advancements in e-cigarettes include optimizing heating structures to prevent burnt flavors, developing new nicotine formulations to mimic traditional cigarettes, and improving liquid supply mechanisms to ensure consistent and enjoyable vapor production. These innovations aim to elevate user satisfaction and replicate the sensory experience of conventional smoking.

Smoore Technology’s redesigned heating assembly avoids burnt flavor while enhancing vaporization.

Traditional cotton core heating elements don’t work very well because they don’t absorb or transfer heat efficiently, which can cause burning and bad flavors. Ceramic heating elements have trouble controlling small holes, so they might not guide liquid well or leak, which affects how well they work.

To resolve this, Smoore Technology has developed a heating assembly that enhances electronic vapes’ liquid absorption and vaporization efficiency. This design ensures the heating component receives a steady liquid supply, preventing problems like burning and bad flavors.

Nicogen’s new formulation delivers better taste and smoke visibility in vapes.

Consumers need nicotine compositions for inhalation that provide a detectable taste, a thicker sensation, and visibility when breathed out, closely mimicking the experience of traditional paper cigarettes. 

Nicogen has innovated a new tobacco formulation to counter this drawback of e-cigarettes. This specific formulation contains nicotine, water, a pH-adjusting agent, polyol, and an amphiphilic agent. It ensures a thicker sensation and detectable taste, providing an exhalation experience similar to traditional cigarettes. It can include flavors and maintain high nicotine purity. 

Innovation 3 – Active liquid supply regulation for uniform taste in vapes

Current liquid supply technologies for electronic atomization devices rely on passive suction and porous ceramic or cotton wicks. These methods don’t evenly distribute the liquid, affecting the taste and user experience. Additionally, micropump solutions have some durability and corrosion resistance issues, affecting reliability and safety.

Shenzhen Maxwell Technology (Smoore’s subsidiary) has created an electronic atomization device with a liquid storage chamber, an atomizing core, and a liquid supply assembly. The device includes a regulator that adjusts the pump chamber’s volume to control the liquid supply to the atomizing core precisely.

The new system improves the taste and user experience by creating a consistent aerosol. It also makes the liquid supply system more durable and safe, solving problems with lifespan and corrosion that valve-based micropumps have.

Conclusion

Companies such as China National Tobacco Corporation and Smoore Technology are effectively addressing key challenges in aroma release and vapor quality to enhance the overall experience. In addition, Aidemar Group and Good Tree International use natural materials and efficient flavor delivery systems, indicating a strong commitment to sustainability. Collectively, these advancements are set to improve product quality and safety while delivering a safer, more stable, and enjoyable user experience.

Exploring such innovations for implementation comes with numerous issues, such as:

• Difficulties in identifying novel inventions among marketing hype
• Understanding the complexities of patents and finding valuable ones among them
• Keeping up with the regulatory constraints, which could unexpectedly hinder the execution of potent ideas

And more! Find the right technologies and understand how these innovations align with your goals through GreyB’s expertise. Fill out the simple form below to schedule an expert consultation today.

Read next: Navigating the FDA Regulations around Tobacco in 2024 and beyond.

Authored by: Lochan Mridul and Ravi Shankar Bhatt, Patent Analytics
Edited by: Hemanth Shenoy, Market Research