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The Development and Advancements of HeatControl™ Technology in IQOS

Juliet Owens

HeatControl™ technology represents a groundbreaking leap in tobacco innovation, designed to radically reduce the health risks associated with smoking while delivering a satisfying tobacco experience. The technology, built into IQOS heated tobacco systems available through retailers such as iTerea, was developed by Philip Morris International (PMI) at their research center in Neuchâtel, Switzerland, as part of a larger commitment to creating a smoke-free future. It took years of extensive research, development and testing before HeatControl™ technology was finally implemented into IQOS, PMI’s flagship heated tobacco product.

More than 400 scientists, engineers, and technicians worked tirelessly to explore every aspect of tobacco heating to create a product that would be a viable alternative to cigarettes. Their aim was to maintain the familiar ritual of smoking but with significantly lower emissions of harmful substances. The result was HeatControl™, a system that heats tobacco instead of burning it, thus eliminating many of the dangerous chemicals associated with combustion.

The Science Behind HeatControl™ Technology

The development of HeatControl™ technology began with a fundamental question: how can tobacco be heated to a sufficient temperature to release its flavor without igniting it? Traditional cigarettes burn tobacco at temperatures that can reach up to 900°C (1,652°F), which produces smoke filled with toxic chemicals like tar, carbon monoxide, and other dangerous substances. By contrast, IQOS heats tobacco to a maximum temperature of approximately 350°C (662°F), a significantly lower range that prevents combustion.

The primary challenge for PMI’s team was to create a heating system that could precisely control temperature while delivering a satisfying user experience. This led to extensive testing of different materials, designs, and heating methods. Among the many prototypes, the flat, wide ceramic blade emerged as the most effective heating element for evenly warming the tobacco.

The ceramic blade’s design allows it to fit perfectly inside the specially designed IQOS tobacco sticks, known as HEETS or Terea sticks in some markets. The blade’s large surface area ensures that heat is distributed evenly, allowing the tobacco to release its natural flavors and nicotine without burning. This innovative approach set the foundation for the highly controlled, smoke-free experience that IQOS offers today.

The Thermocouple Solution: Borrowing from Automotive Technology

An essential aspect of HeatControl™ technology is its precise temperature control. After identifying the ideal heating element, the next challenge was figuring out how to maintain a consistent temperature throughout each use. For this, PMI researchers turned to automotive technology, specifically thermocouples—a device used in car engines to monitor and regulate temperature.

A thermocouple is made up of two dissimilar metals that are joined at one end. When heated, these metals generate a small voltage due to the thermoelectric effect, which can be measured to determine the exact temperature at the junction. By integrating thermocouple technology into the ceramic blade of the IQOS, PMI engineers were able to continuously monitor the temperature of the tobacco during use. This allowed for precise heating and prevented overheating or combustion, which would otherwise release the harmful chemicals associated with traditional smoking.

To further enhance the effectiveness of the thermocouple, PMI utilized platinum and gold in its construction. These precious metals were chosen for their durability, conductivity, and ability to generate consistent, reliable temperature readings. This innovative solution allowed the heating blade to serve dual purposes: heating the tobacco and measuring its temperature, all without the need for additional sensors or components.

The choice of materials and integration of thermocouple technology into IQOS was a major breakthrough, providing users with a consistent, enjoyable experience while significantly reducing the emission of harmful substances.

Comprehensive Testing and Validation

Before launching IQOS to the global market, PMI subjected the device to extensive testing to ensure it met all safety, performance, and regulatory standards. One of the most telling tests took place at PMI’s Research and Development Center in Switzerland, where scientists compared cigarette smoke with the aerosol generated by IQOS.

Using a demonstration machine designed to mimic the act of smoking, PMI researchers compared the filters used in traditional cigarettes to those exposed to IQOS aerosol. After 10 uses, the cigarette filters were stained with a thick yellow layer of tar and harmful chemicals, while the IQOS filters showed minimal discoloration. This stark contrast highlighted the reduced presence of harmful substances in the IQOS aerosol compared to cigarette smoke.

Moreover, PMI conducted a series of clinical and laboratory studies to analyze the toxicological profile of IQOS aerosol. The studies revealed that IQOS emits on average 95% fewer harmful and potentially harmful chemicals than cigarettes. Key toxicants such as carbon monoxide (CO), benzene, and formaldehyde are present in significantly lower concentrations in IQOS aerosol. These findings underscored the potential of IQOS as a harm-reduction tool for adult smokers looking for alternatives to combustible cigarettes.

Key Features of HeatControl™ Technology

IQOS’s HeatControl™ technology offers several distinct advantages that differentiate it from both traditional cigarettes and other tobacco-heating devices. These features are designed to maximize user satisfaction while minimizing exposure to harmful chemicals:

1. Design and Heating System

The heart of IQOS is its advanced heating system, which consists of complex electronics that gently heat the tobacco in specially crafted sticks. The holder, which functions similarly to a traditional cigarette holder, contains the ceramic heating blade. This blade is designed to provide consistent heating without burning, allowing users to enjoy the flavor of real tobacco without the harmful byproducts of combustion.

2. Automatic Shutdown

To ensure a controlled and safe user experience, IQOS devices are programmed to shut down automatically after 14 puffs or 6 minutes of use—whichever comes first. This mimics the duration of a standard cigarette session and prevents the device from overheating or overuse.

3. Single-Use Sticks

IQOS uses specially designed tobacco sticks, which are much smaller and more compact than traditional cigarettes. These sticks contain about 260-320 mg of tobacco material, compared to around 700 mg in a conventional cigarette. Each stick is made up of several components, including a filter mouthpiece, a cooling section, and a tobacco rod. These components work together to provide a smooth and flavorful tobacco experience.

4. Tobacco Composition

The tobacco used in IQOS sticks is highly processed and carefully selected for optimal heating. It is compressed into a uniform rod that ensures even heating and consistent flavor delivery. The design of the stick ensures that the tobacco is only heated—never burned—producing a vapor instead of smoke.

5. Health Considerations

IQOS does not emit tar, the sticky residue produced when tobacco is burned. Instead, it generates an aerosol that contains fewer harmful substances. Scientific studies indicate that IQOS reduces the levels of harmful chemicals by up to 95% compared to regular cigarettes. Additionally, IQOS aerosol contains 98% less carbon monoxide (CO), which is one of the most dangerous gases found in cigarette smoke.

6. Reduced Impact on Teeth Staining

One of the key benefits of IQOS is its reduced impact on teeth staining. Traditional cigarettes are notorious for causing yellowing of the teeth due to the tar and chemicals present in cigarette smoke. In a study conducted in Switzerland, human teeth and dental filling materials were exposed to IQOS aerosol for three weeks. The results showed significantly less staining compared to teeth exposed to regular cigarette smoke, highlighting another advantage of switching to IQOS.

IQOS in Dubai: A Growing Market

The popularity of IQOS has surged in various markets worldwide, and Dubai is no exception. With a growing number of smokers seeking alternatives to traditional cigarettes, IQOS offers a cleaner, more sophisticated option for tobacco enjoyment. The availability of IQOS and its tobacco sticks in the UAE has made it easier for smokers to make the switch to a reduced-risk product.

For example, iTerea, an online retailer in Dubai, offers a wide selection of IQOS devices and accessories at competitive prices. Customers can purchase the IQOS ORIGINALS DUO Silver for just 299 UAE dirhams, along with a variety of tobacco stick flavors to suit individual preferences. This wide availability and affordability have contributed to the growing adoption of IQOS among adult smokers in the region.

Conclusion: The Future of Tobacco with HeatControl™ Technology

HeatControl™ technology represents a pivotal moment in the evolution of tobacco products, offering adult smokers a less harmful alternative to traditional cigarettes. By heating tobacco instead of burning it, IQOS significantly reduces the levels of harmful chemicals that users are exposed to. With advanced thermocouple technology, precise temperature control, and a range of safety features, IQOS delivers a consistent, satisfying tobacco experience without the harmful byproducts of combustion.

As the demand for smoke-free alternatives continues to rise globally, IQOS is poised to lead the charge in transforming the tobacco industry. PMI’s continued investment in research and development underscores its commitment to creating a smoke-free future. With its innovative HeatControl™ technology, IQOS offers smokers a viable pathway to reduce their health risks while enjoying the familiar ritual of smoking.

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