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During the purchasing process, our tobacco experts ensure that only high-quality tobacco leaves are used. The smoker can therefore rest assured that he or she is not only just as well served with fine cut as with factory cigarettes, but also receives a great taste for a favourable price.back to products
The raw tobaccos are stored here ready for weighing. A blend (mixture) can consist of up to 30 different raw tobaccos, so that the blending process is carried out strictly in accordance with the recipes which have been developed by the Blend Manager. One employee weighs the raw tobaccos with the help of the balance on the right-hand side of the picture and fills the mixing ingredients into the tobacco cart until further processing in the vacuum chamber.
The tobacco leaves which have been put together to form a mixture are then moistened in a vacuum chamber with steam and warmed. As a result of the simultaneous drawing of a vacuum, the steam can be absorbed better because the pores of the leaves open. Furthermore, the leaf becomes supple and its brittleness decreases, which is an advantage for further processing.
The structure of the tobacco becomes looser and initial mixing of the mixture ingredients is carried out.
The tobacco leaves collected together to form a mixture are then moistened in a vacuum chamber with steam and warmed. As a result of the simultaneous drawing of a vacuum, the steam can be absorbed better because the pores of the leaves open. Furthermore, the leaf becomes supple and its brittleness decreases, which is an advantage for further processing.
In the steam tunnel the tobacco is moistened through nozzles with steam and warmed so that the casing in the saucing drum is absorbed better and the formation of grit is reduced.
The casing required for this is mixed in the sauce kitchen in accordance with the recipe from natural and nature-identical aromas. In the saucing drum the tobacco is sprayed with the casing. As a result of its rotation, the drum ensures the even application of the sauce and the intensive mixing of the sauced tobacco. During the production of Pueblo (100% tobacco without additives), only water is added to the tobacco.
The sauced tobacco is conveyed to the mixing boxes, where it is distributed evenly in horizontal layers. The mixtures remain for a significant time in the boxes, where the applied casing can be absorbed and moisture equalisation takes place. Due to the vertical removal, mixing of the sauced leaf tobaccos is guaranteed.
The cutting machine is loaded from the mixing boxes. In it, the tobacco is conveyed from two chains located one above the other in a wedge shape to the cutting drum. Six blades attached to the drum cut the tobacco to the desired cutting width, depending on the drum speed and the chain feed motion.
By means of a feeder, the cut tobacco is fed to the roasting process. The cut tobacco is roasted and dried to the desired final moisture in a drum dryer at temperatures of up to 180°C. The water added during the treatment of the tobacco is removed again and as a result of the roasting process, the sauce ingredients combine with the tobacco.
Cooling is subsequently carried out on a cooling belt with a plentiful supply of fresh air. The finished tobaccos are then weighed on a weighing station, filled into boxes and transported to the cut tobacco store.
Cut tobacco store
The finished tobacco is put into immediate storage here and continuously checked with respect to its quality. Monitoring of the tobacco’s moisture plays a very important role here in particular, as the tobacco must not become too moist or too dry.
This is where many a fine-cut tobacco gets its top flavour. These are again natural or nature-identical flavourings, e.g. fruit and spice extracts, which are mostly based on alcohol (brandy, rum, whiskey). In the flavouring drum the top flavour is dispersed over the tobacco by means of a nozzle, giving each tobacco mixture its unmistakable character.
The packaging of smoking tobaccos
In the smoking tobacco packaging process, the tobacco is packed on fully automatic machines. On several packing machines, cardboard tins with different filling quantities are mainly produced. Furthermore, there are wrapping bag packers with different filling quantity requirements. In the rectangular tin packer, only pipe tobacco is vacuum-packed in tin cans. With the vacuum we achieve a long shelf-life. The finished packs are checked by a checkweigher. If the nominal filling quantity does not correspond to the specifications of the packaging regulations, the goods are rejected. After the check of the weight, the pack is provided by machine with a tax strip. Then the finished packs are combined in foil, paper or retail cartons to form trading units. These units are then packed in corrugated cardboard boxes or plastic boxes, stacked on pallets and sent to the finished goods warehouse.
You need nothing more than a filling machine, cigarette tubes and tobacco in order to make your cigarettes yourself. First of all, open the flavour-sealed tin and the closure of the filling machine. Then take out a small quantity of tobacco, spread it loosely and evenly in the filling machine and push it lightly forwards and backwards. Take an empty filter tube and push this over the attachment provided. Now simply close the filling machine, hold the lower section tightly and pull the tube over the tobacco with the carriage mechanism.
And that’s it: your self-filled cigarette is ready.
Open the flavour-sealed tobacco and take out a cigarette paper. Make sure that the gummed surface of the paper is facing upwards. Then use your fingertips to take out the required quantity of tobacco for a self-rolled cigarette and spread this evenly on the paper over the length of the cigarette. Then roll the paper filled with the tobacco evenly between the thumb and index finger of both hands in order to “get it into shape”. Moisten the gummed surface with the tip of your tongue and then perform the final touches.
Remove the excess tobacco and yourself-rolled cigarette is ready.