Cut rag tobacco

production of raw tobacco materials
We supply cut rag tobacco of exceptional quality using the most efficient processing and blending techniques. We strive to achieve 100% customer satisfaction with our products and our service. Our vast supplier and logistics network is ready to handle your toughest orders. Give our service a try and you will always be satisfied. Your business will save time and money and gain access to the finest cut rag tobacco on the market.
Best regards to you and your business, team «Russian tobacco factory»
Competitive advantage
The cost of raw tobacco in traditionally supplying countries has been steadily growing lately along with the expansion of the geography of possible suppliers. Innovative processing technologies have made it possible to develop balanced, high-quality yet cost-effective mixes of a variety of ingredients, including low-cost tobaccos used as fillers and medium to full-flavored raw materials. This trend in blending also means that there is a possibility of optimal use of a wider assortment of varieties and types of tobacco, as well as the fullest possible use of by-products - stems, small particles of tobacco, tobacco leaf waste, recycling waste and tobacco dust.
Currently there is no precise formula for high-quality American-style cigarette mix, although there is a general consensus regarding the components of a tobacco mix in terms of tobacco varieties and categories, as well as the proportion of reconstituted tobacco (Recon), expanded tobacco and expanded stem (CRES).
A competitive advantage based on our economical manufacturing model allows us to scale up production with additional savings passed on directly to our business partners.
Blended tobacco re-imagined
Russian Tobacco Factory is a private limited liability company based in Samara, Russia, engaged in the production, import and wholesale of raw tobacco. In addition to CRS (Cut rolled stems) and Recon (Reconstituted tobacco) production, Russian Tobacco Factory specializes in cut rag tobacco blends.
Using carefully selected tobacco and strictly following the method of its processing, "Russian tobacco factory" has personnel, experience and resources to create unique blends on its own. Blended tobacco "Russian tobacco factory" is available at various price points to meet the special needs of our partners.
Russian Tobacco Factory, in addition to reliability, values confidentiality and offers vast and competitive logistics capabilities. It also offers timely delivery, which allows manufacturers to minimize fees and taxes, as well as reduce storage space at the destination.
At our primary processing facility in Russia, we have everything needed to cut over 4 million kg (8,000,000 lb) of tobacco per year. Our high-tech equipment allows us to cut tobacco according to your requirements to meet the specific needs of your region, as tobacco markets vary widely.
The blended tobacco we offer is based on Burley, Bright, tasty Virginia and aromatic Oriental tobaccos, which we carefully transform into cut rag tobacco. The flavors and casing that we use to emphasize or improve certain specific characteristics are in line with the global modern trends in tobacco products engineering.
Creating tobacco blends is an art, a creative process that begins with the magic of a tobacco master in a laboratory, and ends with an exact adherence to the technological process on the production line. This exciting journey begins with tobacco fields in some of the world's finest tobacco regions and ends with our clients' brands.
The choice is obvious
  • A full range of blends for the following products: Cigarette, Pipe, Roll your Own (RYO) and Make your own (MYO).
  • Wide market segment, from premium to super low cost.
  • Advantageous geographical location. We are closer than it might seem.
  • Creativity when it comes to finding alternative solutions: suggesting the best route, payment terms, offering superior product.
  • Qualified staff who meet all your requirements.
  • A viable and healthy company with low operating costs.
  • No relationship with any company, but loyal to suppliers who offer a good price / quality balance.
  • Our laboratory will become your best friend in the process of finding the perfect blend.
  • A small team with a flexible decision making process.
The choice is obvious
  • A full range of blends for the following products: Cigarette, Pipe, Roll your Own (RYO) and Make your own (MYO).
  • Wide market segment, from premium to super low cost.
  • Advantageous geographical location. We are closer than it might seem.
  • Creativity when it comes to finding alternative solutions: suggesting the best route, payment terms, offering superior product.
  • Qualified staff who meet all your requirements.
  • A viable and healthy company with low operating costs.
  • No relationship with any company, but loyal to suppliers who offer a good price / quality balance.
  • Our laboratory will become your best friend in the process of finding the perfect blend.
  • A small team with a flexible decision making process.
Cut rag blended tobacco production process
Tobacco of the required varieties and sufficient quantities, obtained from different geographical areas, is stored in a warehouse. The initial control of raw tobacco is the first stage of determining the physical and chemical properties of tobacco supplied to the tobacco factory. In tobacco industry, during the manufacturing process of different classes of tobacco products, dozens of varieties of heterogeneous tobacco leaves are used, differing from each other in technological, physio-chemical and morphological properties, and as a result, differently affecting the qualitative and quantitative indicators during the production.

Analyzing the numbers of the main indicators, we see significant differences, for example, the thickness of the tobacco leaf ranges from 0.04 to 0.08 mm, the weight of 1 m2 of the leaf varies in weight from 30 to 67 g, the resin content from 12 to 30 mg / cig., density from 0.5 to 1.2 g / cm3, leaf size from 3 to 60 cm, nicotine content from 0.8 to 2 mg / cig.

This affects a wide variety of physical and chemical properties of tobacco, even within the same variety, which significantly complicates the planning of economic indicators for production and preparation of raw materials for the manufacture of tobacco blends.

The second challenge lies in the fact that the tobacco leaf entering the production line is measured out by weight, and the produced blends used for the manufacture of cigarettes are measured by volume. That is, two cigarettes of same volume may have different weight depending on the types of tobacco used. The degree of filling the volume of the cigarette with the blend is determined by the volumetric elastic properties of the cut tobacco. Using tobacco blends with a higher filling capacity offers higher organoleptic properties, lower amounts of nicotine and tar, and better flammability.

This is why, during the development of the optimal formula for a tobacco blend with constant quality and taste properties, forecasting profits while minimizing the consumption of raw materials is critical. To optimize the production process, it is necessary to have all the information on the volumetric filling capacity of tobacco, that is, in ideal conditions, how much can be produced from a unit of weight of raw tobacco, taking into account technological losses. Thus, planning the amount of finished products produced on the basis of complete information about the properties of each type of tobacco leaf included in the tobacco blend recipe has financial importance.

Adjustment of the composition of the blend is a step that allows tobacco technologists to produce products that tastes the same from year to year. With strict adherence to the approved recipe, a tobacco blend is prepared from various types and commercial varieties of raw tobacco according to smoking characteristics corresponding to the requirements for the particular class of products. If necessary, this step is carried out using the physical and chemical studies of raw materials and previously manufactured products. However, the properties of the same variety of tobacco growing in the same geographical area can vary from batch to batch, depending on agricultural technology, rainfall and post-harvest technology. For this reason, the percentages of the various components in the blend need to be "adjusted" for a consistently "even" taste of the final product.

After the two critical stages of initial control and adjustment of the tobacco blend, the necessary raw materials are sent to the production line, generally, in C-48 corrugated boxes. At the (1) stage of the production of a blend, the tobaccos are unpacked according to the recipe to be used in the production process. The next step is the batch cutting of bales (2) on a guillotine tobacco cutter. The packaging of tobacco greatly varies in weight, from 20 kg. bales to C-48 tobacco corrugated boxes weighing up to 200 kg. The size of the tobacco leaf of different varieties of tobacco also varies widely from 10 to 40 cm, therefore the compressed raw material is cut with vertical cuts for uniform alignment of the components of the mixture according to physical and geometric parameters.

Moistening (3) is a technological operation performed in order to give some elasticity to the raw material to minimize dust losses during cutting and transportation along the conveyor.

Saucing (4) - a technological operation the purpose of which is to change the physical and chemical properties of tobacco, to give the tobacco an improved taste and soften the defects and irregularities of the blend. Saucing (4), moistening and conditioning (3) are carried out in the moistening and conditioning drums, where the dry tobacco leaf is restored to its original size of a green leaf and various kinds of tobacco are evenly mixed in the raw material container.

Tobacco aging is (5) the longest operation in the technological process of preparing a tobacco blend. It takes place in the mixer for 2-3 hours, after layer-by-layer placement of raw tobacco. The purpose of the operation is to evenly distribute moisture and sauce throughout the entire volume of tobacco. Thanks to the length of the process, during the aging stage the components of the sauce penetrate into the inner structure of the tobacco leaf, which gives the cigarette a uniform taste throughout the entire smoking process.
Cutting the tobacco (8) is the main technological process in the preparation of tobacco blends for the manufacture of tobacco products. The purpose of this process is to cut tobacco leaves into bulk pulp with minimal losses in the form of dust particles. The key characteristics of the quality of the bulk pulp are the cut cleanliness and the size of the tobacco fiber, which largely depend on the settings and the quality of the cutting machine. The consistency and stability of the tobacco cutting machine is guaranteed by important elements of the production line: a conveyor belt with a metal detector (6) and a storage device (7).

To minimize dust losses, the optimal moisture content of raw materials is about 20%. The total loss of tobacco throughout the entire technological process of preparing tobacco blends is approximately 6%. Cutting tobacco on a cutting machine allows you to get tobacco fibers with a width of 0.1-0.9 mm. It is at the cutting stage that the settings of the tobacco cutting machine determine the future purpose of blends in terms cigarette formats: king size, queen size, slim size, super slim size or Roll your Own (RYO).

Tobacco drying (9) is an operation necessary to lower the moisture content of tobacco from 20% required for cutting to 13.5% required for the finished product. During the drying process, the tobacco pulp warps under the influence of temperature, the resinous film softens and the adhesion of the fibers decreases. After drying, the volume of tobacco increases, as a result of uneven heating, the fibers that were straight after the machine cutting become twisted. Increasing the temperature for a short time has a positive effect on the smoking properties of the cut tobacco. There is a decrease in nicotine in the tobacco blend and, as a result, the strength goes down to 10%. After the heat treatment, the consumption of tobacco during the manufacture of tobacco products is reduced by 1.2-1.5%. This is due to the improvement of the volumetric-elastic properties thanks to the decrease in fiber bonding and the increase of the filling capacity of the tobacco as a result of twisting during heating. Designs of all kinds of drying devices using different drying methods and, as a result, with different economic costs, are created for the purpose of lowering the moisture content in the tobacco while increasing its volume. So, the percentage of the increase in the volume of the tobacco blend and, as a result, the economic effect on the production depends on the design of the drying device. Also, the cost of blend is influenced by the percentage of cut rolled stems (CRS) or cut rolled expanded stems (CRES) introduced into the recipe through the storage bin (10).

Cooling the tobacco blend in the silo (11) to 25C after the drying step is necessary to prevent the formation of moisture condensation before placing the dried tobacco in the accumulators (tobacco silo) for the cigarette production process. As a result of cooling the cut tobacco, the moisture level is evened out throughout the entire volume of the tobacco mixture.

Aromatization of the tobacco blend (12) takes place in the aromatization drum after adding the expanded stem (CRES) and reconstituted tobacco (Recon). To give the final blend an improved aroma, a low dosage flavoring solution, 0.1 - 0.2% by weight of the tobacco, is evenly applied to the cut tobacco.

The pre-final process of the technological production of a blend is the air separation of the cut raw tobacco (13). Air separation removes fine pieces and tobacco dust. For practical purposes, in production, to assess the quality characteristics of bulk pulp, three types of fractions are distinguished coarse fiber, fine particles, dust. The increased percentage of fine particles and dust in the cut fibrous mass of tobacco raw materials indicates its unsatisfactory level of quality. Thanks to a well-established practice of determining the composition of fractions by particle size using the sieving method, we can talk about the heterogeneity of the three main types of fractions and their different physical properties. Coarse fiber - the fraction remaining on a sieve with holes of a 3 mm diameter. Fine particles cut tobacco fiber, which passed through a sieve with holes of a 3 mm diameter and remains on a sieve with holes of a 0.5 mm diameter. Dust is a type of fraction that has passed through a sieve with a hole diameter of 0.5 mm.

Long fibers are characterized by poor elasticity, excellent deformation, and a good specific volume. The fine particles are known for excellent flowability, good elasticity, and a low specific volume. The dust has a minimum volume and an almost complete absence of characteristics inherent in bulk fiber mass, as a result of this it adversely affects the taste properties of the tobacco product and technological process. As a result of separation, the tobacco blend for the production of cigarettes takes on its final shape.

The finished product is sent by a conveyor belt to the packing and weighing station (14), where it is packed according to industry standards (C-48 boxes with a polyethylene liner) and prepared for further shipment to the client.

Fourteen production stages give a very general outline of the complex process of producing tobacco blends from tobacco leaves called "Primary processing". The final part of the journey of tobacco to becoming a finished tobacco product packaged in consumer packaging is called "Secondary processing".
Blend
Styles of cigarettes
The styles of cigarettes are characterized by the tobacco blends used in their production. The two most common blends are American and Virginia.
Tobacco blend is a mixture of cut tobacco of all kinds of botanical varieties, drying methods and quality classes. All prepared and cut according to the approved recipe for a specific brand of tobacco products. A blend is not a new batch of shredded tobacco made per unit of time, a blend is a recipe that typically contains up to 10 varieties of tobacco. Several names for blend have taken root in the slang of the tobacco industry: shredded tobacco, tobacco mix, pulp.
These days, the trend towards an increase in the consumption of the American blend type cigarettes has become quite prominent all over the world.
American blend
A type of blend consisting of a mixture of Virginia-60%, Burley-20%, Oriental-10%, as well as expanded vein (CRES) or rolled vein (CRS) and reconstituted tobacco (Recon). Usually, additional flavoring and aromatic ingredients are added to American blend cigarettes to compensate for the loss of sugar by Burley tobacco during drying and to give each brand of cigarettes its own unique taste and aroma.
Cigarettes using the American blend are produced following the two-line technological method ... The Burley tobaccos are processed separately from the Virginia and Oriental tobaccos (with the same sauce applied). The Virginia tobaccos are the most weighty part of the blend and contain up to 8 varieties of tobacco, not only different in the method of post-harvest drying, but also different in climatic and geographic zones of growth. Also with the Virginia and Oriental tobaccos, reconstituted tobacco used in the blend is processed in order to reduce the overall level of nicotine and tar, as well as to reduce the cost of the blend . Expanded stem (CRES) or rolled stem (CRS) is used as a filler with good bulk properties, improving the flammability of a cigarette, reducing tar and nicotine content, and also to lower the cost of the blend. Raw tobacco material, such as expanded stem or reconstituted tobacco has a characteristic cellulose flavor, which limits its maximum use in blends, despite the low price. As a rule, in practice, when creating the blend recipe, tobacco raw materials are used in proportions that provide an optimal taste to price ratio.
Virginia Blend
Virginia tobacco blend is based on Virginia tobaccos. In some exceptions, Virginia blends, referred to as modified, use Burley or Oriental. With rare exceptions, sauces and flavors are used in this type of blend. Virginia tobacco blends are popular in Canada, Malaysia, Nigeria, Great Britain, India, Pakistan, Australia and South Africa. The leading market for the production and consumption of cigarettes in China is dominated by cigarettes from a Virginia tobacco blend. Because Virginia tobaccos, both light and soft, are low on nicotine, Virginia blend is used in many light cigarettes.
Other blends
The two types of blends American and Virginia considered here are the most common ones in the world. All other types of blends are combinations of recipes based on Virginia blend and American blend: German blend (oriental tobaccos up to 50%), English blend (consists of 3-4 types of Virginia tobacco, no sauce, but sometimes flavored), European blend (mix of the American and German and usually less flavored), International blend (Virginia 80% and Oriental tobacco 20%), Oriental blend (consists of only oriental tobaccos).
advantages
Attractive price and excellent quality.
Ready-made and custom blends
Ready-made blends (American blend, Virginia blend, Oriental blend) for the production of tobacco products. Both according to proven recipes and custom. Using carefully selected tobacco and closely following the manufacturing process, the Russian tobacco factory can produce a wide variety of cut rag tobacco.
Many options
Cutting width from 0.1 to 0.9 mm. For king size, queen size, slim size, super slim size and for Roll your Own (RYO) format. Since markets in different parts of the world have different requirements, our high-tech equipment allows us to cut tobacco in various sizes to meet the individual specifications of your production.
Low price
Having our own line of rolled stem (analogue of the expanded stem) and reconstituted tobacco allows for a full control of the component composition and the low price of the tobacco blends we produce. Our tobacco cutting line, to achieve a balance of price / quality, on request produces: sauce, flavoring, CRS, CRES, Recon and / or homogenized tobacco.
What makes an average blend, a good blend?
Classic answer: "It's all about tobacco!"
Modern answer: “It's about the combination of tobacco blending expertise, processing methods and production technology! "
In recent decades, the tobacco industry has undergone dramatic changes that have affected the entire range of production factors - from raw materials at the tobacco plantation to tobacco products in a factory. The society is striving to reduce risks. These changes have affected all aspects of the cigarette manufacturing process. Today we are witnessing an unprecedented transformation. Health awareness is at its highest, technology is top notch, and consumers are ready to experiment.
By choosing "Russian Tobacco Factory" you keep your finger on the pulse of the ever-changing system of technologies and global trends in the tobacco industry.
Get in touch with us today in any way that is convenient to you, and we will discuss common points and ways we can help each other tomorrow.