Recon tobacco

production of raw tobacco

Today reconstituted tobacco is regarded as an essential component of any quality and cost-effective brand of cigarettes, as it improves the physical and sensory properties of the product, as well as the chemical composition of the smoke.
Dr. Fawky Abdallah Cigarette Product Development
PROPER USE OF BY-PRODUCTS

Reconstituted tobacco leaf is a new technology in the field of recoverable resources in the tobacco industry. It is now widely used in the tobacco industry to create modern blends. After removing the stems from the tobacco leaf, the weight of tobacco raw materials becomes 68-78% of what it originally was. Approximately 22-32% of the losses are attributed not only to moisture loss, but also to by-products such as stems, tobacco leaf particles, tobacco fines and dust, which cannot be used as they are. We return these recultivation residues of tobacco leaves after the production of tobacco blends, which could be disposed of and wasted, into the technological process in the form of a pliable material with a high-quality set of characteristics. This raw material can be used in a tobacco blend in combination with cut tobacco for cigarette production.
Advances in tobacco chemistry and technology at this stage allow us to produce a new generation of reconstituted tobacco using the pressing method. While this technology is more efficient , it also produces many different types of high-quality and cost-effective reconstituted tobacco that can be used in blends and various types of cigarettes and cigars.
advantages of recon tobacco
At first, reconstituted tobacco was used by tobacco technologists for economic reasons as a cost-reducing additive. Today, it is an integral part of any American blend cigarette, as it improves the physical and sensory properties of the product, as well as the chemical properties of the smoke.
Today advances in reconstituted tobacco production technology allow us to obtain a product with specified characteristics, which is close to natural tobacco and has excellent smoking properties.
The cost of raw tobacco in traditional supplying countries has been steadily growing lately along with the expansion of the geography of possible suppliers. Innovative tobacco reconstitution technologies have made it possible to develop balanced, high-quality, yet cost-effective blends.
Depending on the type and properties of by-products, as well as the technology used for obtaining reconstituted tobacco, the tar content in it is 30-50% lower than in the original raw tobacco. For example, tobacco by-products with a resin content of 20 mg on average produce reconstituted tobacco with a resin content of about 10-15 mg.
In addition to reducing tar levels, the use of reconstituted tobacco plays an important role in reducing its carcinogenic activity. The biological activity of reconstituted tobacco smoke is approximately 70% lower than that of natural tobacco smoke.
Not all reconstituted tobacco is created equal. The method we use, is based on the latest advances in the organization of production and product development, it allows us to obtain many varieties of reconstituted tobacco with desired properties.
Recon tobacco characteristics
  • Sheet thickness - no more than 0.25 mm
  • Moisture - 11.5-13.5%
  • Shape - sheets 10x10 cm / thin-cut fibers 0.9 mm wide
  • Nicotine - 0.6-0.7%
  • Carbohydrates - 10-12%
  • Chlorides - less than 1.0%
  • Weight of 1 m2 - 85-110 g
  • Percentage of water-soluble substances by weight - not less than 30%
  • Color - from light brown to dark brown
  • Smell - pronounced tobacco
  • Shelf life - 12 months
  • Type of packaging - C-48 corrugated box with a polyethylene liner
Recon tobacco characteristics
  • Sheet thickness - no more than 0.25 mm
  • Moisture - 11.5-13.5%
  • Shape - sheets 10x10 cm / thin-cut fibers 0.9 mm wide
  • Nicotine - 0.6-0.7%
  • Carbohydrates - 10-12%
  • Chlorides - less than 1.0%
  • Weight of 1 m2 - 85-110 g.
  • Percentage of water-soluble substances by weight - not less than 30%
  • Color - from light brown to dark brown
  • Smell - pronounced tobacco
  • Shelf life - 12 months
  • Type of packaging - C-48 corrugated box with a polyethylene liner
Technological features
The economic effect is achieved by saving on the expensive tobacco leaf
Profitability
The process of producing reconstituted tobacco was developed more than 50 years ago for economic reasons as a method of processing by-products or part of them by converting them into a tobacco sheet that is more amenable to the processes involved in mixing, processing and manufacturing of cigarettes.
Efficiency
The possibility of using both the classic form of reconstituted tobacco - in sheets 10 x 10 cm, and the thin-cut form with a width of 0.9 mm will allow the tobacco maker to effectively design the composition of the final blend, in terms of economic parameters, physical properties - increasing filling capacity, chemical composition of smoke - reducing levels of tar and nicotine, and smoking properties - helping to preserve the overall bouquet of the composition.
Technology
At 20-25% of the total mix, reconstituted tobacco can be considered part of the skeletal blend, with the added advantage that its properties do not change over time, since reconstituted tobacco is much less influenced by the negative impact of growing conditions, market fluctuations and other variables that affect the quality and cost of other varieties and categories of tobacco that make up the skeletal blend.

The results of using reconstituted tobacco produced using our technology are slightly different from the results of using natural tobacco in primary processing: mixing, preparation, pre-soucing , cutting, drying, cooling and final flavoring - as well as during the production of cigarettes.
Production method
The process of producing reconstituted tobacco is automated: the participation of operators is limited to controlling the operating mode of the elements of the production line through special devices at the technological control post.

The process begins with loading the dispenser (1) with tobacco by-products. The raw material is fed into the dispenser with a pneumatic lift. The materials are carefully sieved to avoid clumping during further moistening. To facilitate grinding and save energy, the material is preheated in a heat sleeve to reduce the moisture content to no more than 8%.

The material is then sent to the fine grinding mill (2). After grinding in the mill, the crushed dry product is sent to the calibration system of tobacco by-products (3). After passing through this system it is fed into the storage system (5a, 5b) using a pneumatic unloader (4). At this time, the liquid component begins to be prepared in the kitchen (7). Liquid additives: propylene glycol, glycerin and others - are mixed with water and stored in reservoir tanks.

The dry and liquid components are mixed in the mixing device (8), into which the dry component is fed from the storage system through a dispenser (6) and the liquid ingredient is delivered from the kitchen. The dosage of each component depends on the required characteristics of the final product.
The dosage of each component depends on the required characteristics of the final product.

By means of a conveyor belt with a metal detector (9), the resulting solution is transported to a sheet forming machine (10). At this stage, the solution is dried into a paste with a moisture content of 35-40%. The purpose of this process is to reduce the amount of liquid, which will help save energy during the drying step.

Using the spreader, the paste is evenly applied to the belt, forming an even layer. The formed plate is transported to the drying oven (11), which is a multi-stage air-convection oven, which creates a uniform temperature throughout the entire internal volume.

The dried plate is fed from the oven using a belt conveyor (12) into a forming machine (13), here it acquires its marketable appearance - reconstituted tobacco in the form of sheets 10x10 cm, or in the form of thin-cut fibers 0.9 mm wide, depending on the required format of the final product.

The finished product is sent to the packaging and weighing station (15) using a conveyor belt (14) where it is packaged according to industry standards (C48 boxes with polyethylene liner) and prepared for further shipment to the client.
Reconstituted tobacco is an ideal raw material tobacco to be used as a component of a tobacco blend:
  • Cut Recon.The possibility of supplying both the classic form of sheets 10 x 10 cm, and thin-cut fibers with a width of 0.9 mm.
  • Quality of raw materials. The most reliable suppliers of tobacco by-products have been chosen, guaranteeing regular deliveries throughout the year and the constancy of the physical and chemical qualities of the original tobacco raw materials.
  • Product quality. The production process of reconstituted tobacco is fully automated.
  • Certified production. A number of production management systems have been implemented: ISO 9001, ISO 14001, ISO 18001.
Welcome to the future of tobacco!

Reconstitution technology that produces an excellent end product - Reconstituted Tobacco Leaf.

Technology that allows you to fully control the parameters of nicotine, sugar and the aroma of tobacco blends. A technology that provides high volumetric filling, low breakdown rates and powerful economic benefits, as well as excellent aroma retention - which is especially important with Burley and oriental tobaccos.