Recon tobacco
production of raw tobacco
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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.
In 2021, the worldwide recon tobacco industry expanded by $8 million, even amidst the global crisis. This burgeoning market requires a cost-effective, innovative solution, and the Russian Tobacco Factory is ready to provide it to all cigarette producers.
The first Recon Tobacco which is created by rolling on rolls and which retains its shape even in DCC.
Recon tobacco is a versatile product in the tobacco market, initially designed to reintegrate costly stems and scrap tobacco into production. Amidst the wave of tobacco control, it gained an additional benefit - the reduction of nicotine and tar content. Recon tobacco is primarily seen as a filler for cut rag tobacco, even though it has various applications in the tobacco industry, such as in cigarette paper, tobacco paper, and as a substitute for cigar wrappers and binders.
Our Recon Tobacco is the outcome of extensive laboratory research, resulting in enhanced strength and elasticity. Multiple tests conducted by cigarette manufacturers confirm its high standards. It has the capability to pass through the Direct Condition Cylinder (DCC) on the Primary Processing Line.
Our Recon Tobacco is the outcome of extensive laboratory research, resulting in enhanced strength and elasticity. Multiple tests conducted by cigarette manufacturers confirm its high standards. It has the capability to pass through the Direct Condition Cylinder (DCC) on the Primary Processing Line.
All methods of producing recon tobacco
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The excellence and competitive pricing of reconstituted tobacco begins with the blueprint of the plant's design.
Let's exclude the outdated method of adhering tobacco powder to paper from our discussion. It is difficult for us to consider a product with 80% paper content as recon tobacco.
Paper making recon tobacco and slurry recon tobacco
The paper and slurry methods, once widely used technologies from the previous century, have now reached their limits. These processes are well understood and researched, but they are unlikely to produce groundbreaking innovations. They fail to address key challenges for efficient production, such as reducing water consumption, lowering energy costs for water removal from suspensions, minimizing environmental impact, and effectively controlling the moisture content and consistency of the final product.
The paper and slurry methods persisted for many years due to a lack of alternatives. Tobacco technologists did not require additional equipment for the cut rag tobacco line, nor did they need extra manpower. The handling of recon tobacco was identical to that of natural tobacco leaf.
The paper and slurry methods persisted for many years due to a lack of alternatives. Tobacco technologists did not require additional equipment for the cut rag tobacco line, nor did they need extra manpower. The handling of recon tobacco was identical to that of natural tobacco leaf.
Recon tobacco rolling process on rollers
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Contemporary advancements in recon tobacco production.
The rolling process is a type of pressing technique in which a tobacco sheet is formed under high pressure. It is known by trade names such as nano-fiber recon (pioneered by Recon INC. Brazil and Comas SPA Brazil), and the extrusion method. Flexible, gentle, efficient, and future-oriented – these are the crucial characteristics for tobacco industry production facilities. The rolling process for producing recon tobacco aligns with these principles, but with one minor drawback – it lacks the ability to pass through Direct Condition Cylinders (DCC). In a DCC, this type of recon tobacco breaks down into small fragments, requiring careful handling.
We have revolutionized the recon tobacco industry
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We've incorporated the finest aspects of roller-rolling technology while adding a new dimension - true tensile strength. Our recon tobacco is the first of its kind, created using the roller-rolling method, to successfully pass through the DCC.
- High strength attributes are not just mere claims.When utilizing reconstituted tobacco from your supplier, do you load it into the slicer or after the DCC? If it's loaded into the slicer and produced by the paper or slurry method, you're likely purchasing a costly recon tobacco product.
- Using less water results in more affordable recon tobacco.Traditional methods consume significant amounts of water, which must be evaporated during the drying process. By design, these methods are not the most cost-effective options.
- The uniqueness of our approach lies in the simplicity of the concept, while the challenge rests in its execution.Our technology avoids the costly process of producing nano-fiber cellulose. Our product contains 90% tobacco and the minimal amount of adhesives necessary. Our proprietary method involves multi-stage rolling with the proper roller friction. We enhance the strength properties of recon tobacco through mechanical action alone, minimizing the use of chemicals.
- Eco-friendliness is a crucial demand in today's world.Our process does not provoke protests from environmentalists concerning the discharge of wastewater into natural water sources, as we generate no such waste.
The advantages for you are clear. By significantly reducing the production costs of cigarettes, you can achieve substantial economic savings.
Could it be the right moment for a new collaboration?
Reliable Recon Tobacco Supplier.
- The Russian Tobacco Factory is globally recognized as a dependable and efficient supplier of recon tobacco, with a significant portion of our business devoted to managing B2B relationships. Buy wholesale recon tobacco directly from the factory.
- Recon tobacco leaf is crucial in cigarette production and can be derived from either the customer's byproducts or specially sourced tobaccos.
- We provide a variety of standard recon tobacco leaf options, such as Ready-to-Use, American Blend/Virginia, and Oriental/Burley, which are available for immediate use or for sale with minimal wait time.
- Our Recon Tobacco offers notable cost benefits for blending, allowing manufacturers to create competitive cigarette products by combining recon and virgin tobacco in various ratios. This is particularly important in emerging markets, where a competitive edge in pricing and quality is vital for success and market share growth.
- Traditional recon tobacco sheet production methods involve a high glycerin-to-water ratio of up to 95% during processing. In contrast, our approach yields tobacco materials with significantly lower moisture content (20-40%), resulting in faster drying times and reduced nicotine and flavor loss. The Russian Tobacco Factory also minimizes binder usage, leading to a higher tobacco content of up to 90% and a reduced impact on flavor during combustion.
- We have the expertise to produce top-quality recon tobacco suitable for American and English/Canadian blends. These products can be integrated into our existing blends or tailored for use in your blend. We can also supply recon tobacco in its original form, customized to meet your specific requirements.
- The low moisture content of recon tobacco positively impacts environmental sustainability, as shorter drying times and decreased energy consumption result in lower production costs compared to competitors.
- Our tobacco slurry features a solid consistency, unlike conventional recon tobacco production systems, making it easy to roll uniformly and control thickness using rollers. This consistency in rolling contributes to uniformity in subsequent processes and helps maintain key product attributes, such as nicotine content, within the desired range.
- We are more accessible than you might think. With extensive experience in customs operations and the B2B tobacco business, we welcome you to visit and witness the bears playing the balalaika.
Experience a cost-effective solution with our recon tobacco, offering better blend optimization.
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The only competitive product we see on the market is natural tobacco leaf.
Recon tobacco seamlessly undergoes all stages of primary tobacco processing (blending, casing, conditioning, cutting, drying, flavoring, cooling, air pneumatic transport), comparable to the behavior of tobacco strips. Comparing our recon tobacco and natural tobacco leaf:
- Supreme Affordability: A Budget-Friendly Substitute.Recon tobacco is revolutionizing affordability in the tobacco market. Generally, it is at least 50% cheaper than natural tobacco leaf, making it a significantly more cost-effective option. Market conditions and tobacco leaf type variations can influence price differences, but the overall cost reduction remains indisputable. The blend's economical components, with substitution rates between 10 to 20 percent and greater filling power than tobacco lamina, promote exceptional blend cost optimization.
- Waste Minimization: Refining the Manufacturing Workflow.By integrating recon tobacco leaf into the cut rag tobacco blend, cigarette machine waste can be curtailed by up to 5%. The degree of waste reduction may differ depending on the specific blend and manufacturing process, but it often leads to enhanced efficiency and reduced overall production expenses.
- Steadfast Consistency: Uniformity in Dimensions and Density.Recon tobacco delivers unmatched consistency in size, shape, and density compared to natural tobacco leaves. This uniformity significantly improves the production process by reducing the possibility of machine jams or other issues that could create waste.
- Precision Property Management: Perfecting the Cigarette Production.The manufacturing process of recon tobacco enables producers to control and adjust properties such as burn rate, moisture content, and density with accuracy. These modifications contribute to a more streamlined and effective cigarette-making procedure.
- Durable and Sturdy: Superior Breakage Resistance.Recon tobacco typically demonstrates increased resilience during secondary manufacturing stages, minimizing the risk of breakage. The carefully chosen ingredients in the composition enhance strength and aid in waste reduction, ensuring a more dependable product.
- Unrivaled Process Control and Standardization: Consistency and Cost Efficiency.The recon tobacco manufacturing process offers exceptional control over the end product's properties and characteristics. This high degree of standardization results in consistent quality and decreased secondary processing costs, making it an economical solution for the tobacco sector.
- Exploiting Economies of Scale: Leveraging Large-Scale Production.Large-scale production of recon tobacco has the potential for substantial profitability. As recon tobacco output grows, manufacturers can refine their processes and reduce expenses, leading to lower costs per unit of production.
Recon tobacco brings a wealth of benefits to the tobacco industry, from unmatched affordability to reduced waste and enhanced property control. This innovative product is revolutionizing the way tobacco is produced and consumed, offering a cost-effective and efficient alternative to traditional tobacco leaves.
Perhaps it's time to consider reconstituted tobacco over traditional tobacco strips and begin reaping financial benefits?
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 pliablematerial with a high-quality set of characteristics. This raw material can be used in a tobacco blend in combination withcut tobacco for cigarette production.
Advances in tobacco chemistry and technologyat this stage allow us toproduce 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.
Advances in tobacco chemistry and technologyat this stage allow us toproduce 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
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.
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.
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.
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 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.
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.
Would you like to get a sample of reconstituted tobacco or an offer?
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.
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.