Tobacco is an agricultural product and much of its processing and handling is like that of food products. However, one primary difference is that the only postharvest insect of any major concern to the tobacco industry, especially in North America, is the cigarette beetle, Lasioderma serricorne (Coleoptera: Ptinidae) (from this point on referred to as “CB”). The CB is also a major pest of postharvest foods, particularly processed grain products like pet food, animal feed, and also dried herbs and spices. In the United States, the CB occurs commonly in food and tobacco warehouses, especially those in the southern part of the country. As a “tropical” insect species, it is understandable that the CB has a more southern distribution in the United States and that it is not commonly found in geographic regions where there are many days a year of below-freezing temperatures. Nevertheless, CBs can be found inside northern tobacco and food plants and finished-product warehouses in which the temperatures are favorable all year round and endemic populations persist solely on spilled food and tobacco dust that is not removed or cleaned.
The CB has been the target of substantial research that has determined important aspects of its population dynamics. The optimum temperature for development of larvae through adults, the number of eggs laid per female and the effects of different food sources on development of CB brood are well known (A
In the United States, for example, insect infestation in the food industry, and the application of control methods against insect infestation in commercial food, is overseen by the U.S. Food and Drug Administration (FDA) and other regulatory agencies (e.g., at the state level) as potentially unsafe contamination. For example, the FDA has set “actionable levels” for insect fragments in food, such as 75 or more insect fragments per 100 g of wheat flour (FDA, 1998). Similar requirements are currently not required for tobacco products (https://www.fda.gov/tobacco-products/rules-regulations-and-guidance/rules-and-regulations). The U.S. Environmental Protection Agency (EPA) sets maximum allowable residue (MRL) tolerance levels of registered pesticides in foods at different points in the supply chain. Higher MRLs tend to be allowed in raw products compared to MRLs in finished food products for customers. For example, raw wheat grain in storage bins can have 8 ppm of the insecticide Malathion, but allowable levels in finished food products from wheat (e.g., flour, breads, breakfast cereals, etc.) are set much lower. The EPA regulates the specific pesticides that may be used on tobacco and other crops and specifies how the pesticides may be used, but the agency does not otherwise regulate residues of pesticides approved for use on tobacco. The U.S. Department of Agriculture (USDA), however, is required by Title II of the Dairy and Tobacco Adjustment Act to test imported and domestic tobacco for residues of pesticides not approved by EPA for use on tobacco that federal officials believe are used in other countries (see https://www.govinfo.gov/content/pkg/STATUTE-97/pdf/-STATUTE-97-Pg1128.pdf#page=24). Guidance on residue levels have been developed by the Agro-Chemical Advisory Committee (ACAC) of the Cooperation Centre of Scientific Research Relative to Tobacco (CORESTA) to provide guidance to tobacco growers and those in the tobacco industry interested in the application of crop protection agents and the implementation of good agricultural practice in tobacco production (CORESTA, 2021).
Cured tobacco leaves are commonly stored in warehouses for two years or more, where they can be subject to CB infestation (E
In the cigarette industry, it is common practice to expand the tobacco (ET) to increase its filling capacity and volume (http://www.tobaccorag.com/products/expanded-tobacco). The process that results in ET would also have lethal temperatures for CBs. However, not all of the tobacco is subjected to this process and CB infestation may happen further down the processing and packing lines following ET. Tobacco manufacturing plants vary in the degree of housekeeping. Tobacco dust tends to be common throughout a facility. Dust residing in hard-to-clean locations for periods longer than four weeks, and subjected to warm temperatures, will easily support an “in-house” population of CBs that is independent of what flies in through open doors or what comes in with the raw tobacco. Therefore, pheromone traps for CBs should be placed at recommended intervals (horizontally as well as vertically) for effective monitoring of the insect. By constantly monitoring for CBs, it may be possible to detect an unwanted infestation before it occurs. CBs may become established as a year-round endemic population at a tobacco facility, or as a collection of many sub-populations according to distinct physical locations within a manufacturing plant and related buildings. Natural CB immigration or CBs from incoming raw leaf product may occur but is likely to be inconsequential once the product is heated. Thus, most CB activity discovered in later parts of the product flow likely comes from beetles already on-site that likely represent well-established populations. Large quantities of tobacco dust contribute to maintenance of endemic CB populations. Beetles hide and persist on small amounts of food for a long time, and easily survive cleaning if such cleaning does not uncover all hidden tobacco dust or hidden product debris. Only very thorough heat treatment or fumigation with an active, effective chemical fumigant (e.g., phosphine, sulfuryl fluoride) in a well-sealed environment can effectively rid the facility of CBs. However, heat treatment or fumigation may be impractical or unsafe in many locations inside tobacco manufacturing plants. Heat treatments that are incorrectly done may not reach temperatures need to kill insects, or may be too high as to damage some equipment. Phosphine is corrosive to copper and other metals in electrical equipment and therefore fumigations with phosphine inside a manufacturing facility can damage any exposed computer or heating, ventilation, air conditioning or other electrical equipment.
A key aspect of CB behavior and life cycle is the female-produced sex pheromone that attracts males for mating. A synthetic formulation of the major pheromone component is commercially available for use in traps to detect the presence of CBs and monitor males within, throughout and outside tobacco facilities over time (C
The CB infestation triangle (Figure 1) illustrates that the existence of an infestation caused by CBs absolutely requires the interaction of adequate food sources for the beetles (cured leaves, dusts, finished products, etc.), presence of a CB infestation at a given population size (low vs. high), and an environment favorable for infestation development. Simply, CB infestation will not occur if the beetle is prevented from invading warehouses, manufacturing plants and finished-product environments, or if the food sources are removed, or the environmental conditions are not favorable (e.g., too hot or too cold). The severity of CB infestation depends on the favorable level of each factor. Thus, CB infestation can be prevented upon elimination of any one of these three causal components. Integrated Pest Management (IPM) requires that adequate measures be in place to help prevent an unacceptable increase in a pest population. Regular monitoring of the pest population and key aspects of the environment conducive for population increase must be practiced along with frequent decision-making for effective mitigation (e.g., fumigation) of the CB population when needed, or to continue with regular prevention and monitoring when mitigation is not needed (H
Figure 1
Cigarette beetle infestation triangle of variables needed to be favorable for a CB infestation.

Intensive and dedicated cleaning of tobacco dust in areas that may be the primary sources of CBs is a critical tool to lower or prevent infestations. Sanitation must include the opening, and possibly disassembly, of ALL equipment and machinery to vacuum out the dust and potential resident insects. Commonly used “blow-down” of dust and debris from above-floor surfaces can prove ineffective to reduce pests as dust will simply be relocated to other hidden spaces. If ledges and other surfaces are blown down, then the tobacco dust and debris with insects must be vacuumed, removed and discarded off-site. These practices will require a dedicated and experienced cleaning crew that is knowledgeable in non-liquid cleaning practices and who can operate during all production times. Therefore, proper sanitation for pest prevention must be part of the routine standard operating procedures of the facility.
There are few options for spraying common residual insecticides such as organophosphates or pyrethroids in tobacco storage and processing buildings. Common residuals like chlorpyriphos or deltamethrin are registered in the U.S. for commonly performed “crack-and-crevice” spray application in buildings used for food storage and processing (application label for deltamethrin https://www3.epa.-gov/pesticides/chem_search/ppls/000432-01514-20110419.pdf). Similar applications in tobacco buildings are not clearly stated on the product application labels, though “pantry pest” target would include the CB. Maximum pesticide residue levels permitted in foods are established, but residue levels in a non-food consumable like tobacco are not clearly reported. Low-risk residual chemical insecticides, such as insect growth regulators (IGRs), may have registrations for tobacco buildings and are known to be effective for controlling CBs and preventing them from infesting bulk or processed tobacco. IGRs are insect juvenile hormone “mimics” that do not have acute toxicity, but rather disrupt the normal development of the insect as it molts from one stage to another. The adult stage is never reached or is terribly disfigured and non-reproductive, and the insect population eventually dies out several weeks after treatment. One such registered insect IGR, pyriproxyfen, is labeled for use as a surface or spot treatment for stored-product pest control in food facilities in the United States (A
Packages for raw materials or finished tobacco products can be developed that are resistant to insect penetration and infestation (M
Figure 2
A large storage of boxes containing dry-cured tobacco for long-term storage being prepared for coverage with a long-last insecticide-treated netting called Carifend® (by BASF, https://agriculture.basf.com/global/en/business-areas/urban-and-rural-pest-control/use_areas/stored-product-pest-control.html).

Routine trapping with the CB-specific sex pheromone remains an extremely important practice to detect the presence of CBs and to monitor this pest in many locations inside or outside a building over time. Pheromone-traps let the pest manager know when CB numbers are exceeding action thresholds, and to determine if numbers remain low following a critical mitigation like fumigation (C
Pheromone traps placed 1.5–2.0 m above the floor are considered in the best position for monitoring the CB in most agricultural landscapes (E
Figure 3
The practice of integrated pest management that monitors changes in pest numbers and product damage along with decisions for effective control (e.g., fumigation) before loss of profit. Modified from H

Hydrogen phosphide, known as phosphine gas (PH3), is the most widely used fumigant for raw bulk-stored agricultural commodities, including tobacco, worldwide. Phosphine is typically used for bulk-stored grain in large silos or metal bins, and is applied to large-scale warehouses for dried fruits, nuts and tobacco (Figure 4). Sealing of bins and buildings must be as gas-tight as possible to prevent large losses of gas during fumigation. Buildings in which phosphine fumigations are done should have minimal electrical appliance, perhaps only easily replaced lighting, because phosphine is highly corrosive to copper and other metals (T
Figure 4
Gas-tight sealing for fumigation of stored tobacco showing typical situations for application of phosphine. Top-left is the inside of a warehouse prior to sealing openings to the outside, Top-right is a series of warehouses onto which windows have been sealed with thick cellophane and duct tape. Bottom-left is an example of a loading dock door that is sealed for fumigation. Bottom-right is a collection of a few boxes covered and sealed for localized, small fumigation.

Many species of stored-product insects have developed resistance to phosphine over the past 50 years, and the CB is one of those with resistant populations (N
Figure 5
The Degesch™ phosphine tolerance test kit (left) (https://detia-garda.de/wp-content/uploads/2019/05/Phosphine-Tolerance-Test-Manual.pdf). The kit includes two small pellets of magnesium phosphide, a 3.7-L plastic water jug in which the pellets are reacted with a small amount of water to generate an atmosphere of 6,000 ppm phosphine (left image). A small group of beetles are placed in a large see-through plastic syringe before a blend of gas and air is added to the barrel to result in a concentration of 3000 ppm phosphine. Beetles are observed for 30 min to count the number of susceptible beetles that are knocked-down by the phosphine. Beetles that remain upright and appear normal are scored as resistant.

There is at least one registered fumigant that can be used in tobacco facilities, and several others with similar registrations that could potentially be registered in the US. SF is registered for post-harvest agriculture commodities under the commercial name ProFume® (see EPA-approved application label at http://profume.com/wp-content/uploads/2019/09/20180730-ProFume-Specimen-Label_SA_clean.pdf). SF can effectively kill many pests, although the egg stage of some arthropod species is the most difficult to kill (P
Heat treatment of the entire building can be an effective fumigant alternative for killing stored-product insects, including all life stages of the CB (A
Figure 6
A portable heat-treatment device for delivering hot air into a flourmill from outdoors to control insects (top), and a hot-air blower operating inside a mill that is plumbed into the building's steam.

A change in the natural atmosphere around a commodity to become insecticidal can be achieved in a gas-tight structure (N
Figure 7
A GrainPro cocoon containing bagged commodity subjected to a low oxygen atmosphere using a vacuum pump to achieve approximately 1% oxygen. The same gas-tight covering could be used for tobacco under low O2 (via vacuum or high N2), high CO2, or a small application of a fumigant.

The mating behavior of CBs can be interrupted using pheromone-based mating disruption (MD), a well-known biologically-based method that is very safe and used throughout agriculture for over 40 years, including stored product insects (P
Figure 8
Mean ± SE number of CBs captured in sticky traps in treated mills 8 weeks before and after mating disruption. Mean number of beetles for a given mill followed by different letters are significantly different (P ≤ 0.05) (Adapted from M

The beetle-specific insecticidal bacterium called Bacillus thuringiensis tenebrionis (Bt) could be applied to the CB in various ways (B
Tobacco companies with CB activity need to have a “toolbox” of effective pest management techniques and control methods. It is expected that sometime in the near future the FDA will issue its guidance for Good Manufacturing Practices (GMP) for the tobacco industry. Implementing the tools outlined in this paper will lead to effective control of the CB and prepare facilities for GMP regulations. Avoiding use of chemical insecticides is desirable; however, cleaning alone may not be an effective form of pest control. Integrated Pest Management, or IPM, in any pest system includes the basic components of prevention, monitoring the pest population, and then uses monitoring data in facility-specific decision-making to either continue with sanitation and prevention, or take action with definitive methods of pest control like fumigation. Prevention is accomplished by keeping pests away from the protected product and engaging in vigilant sanitation to make sure that unprotected product is not exposed so that it too will not become infested. Monitoring should be done of the pest insect population (CB), the product being protected (tobacco) and the environment (temperature, relative humidity, lighting levels, etc.) where the pest and the product potentially co-exist. If pest monitoring determines that an established action threshold level has been reached, then action in the form of effective pest mitigation should be applied.