Reconstituted 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 global reconstituted tobacco leaf (RTL) market continued to grow by $8 million despite the global crisis. This growing market needs an innovative low-cost product - Russian Tobacco Factory offers it to all cigarette manufacturers.
The first reconstituted pressed tobacco capable of passing the Primary processing line from start to finish
Reconstituted tobacco is a multi-faced product on the tobacco market. It was created with one purpose - to bring expensive stems and scrap tobacco back into production. Subsequently, in the wave of tobacco control, another value was added - reduction of nicotine and TAR. We see reconstituted tobacco as a filler for cut rag tobacco (Reconstituted cigarette filler). Despite the variety of uses in the tobacco industry (Reconstituted for cigarette paper, tobacco paper, cigar wrapper and binder substitute).
Our Reconstituted Tobacco is the result of much laboratory work. As a result, we have obtained strength and elasticity. Numerous tests by cigarette companies confirm the high standards. The ability to pass Direct Condition Cylinder (DCC) on the Primary Processing Line.
Our Reconstituted Tobacco is the result of much laboratory work. As a result, we have obtained strength and elasticity. Numerous tests by cigarette companies confirm the high standards. The ability to pass Direct Condition Cylinder (DCC) on the Primary Processing Line.
Existing methods of creating reconstituted tobacco
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The quality and good price of reconstituted tobacco starts with the plant's design documentation.
Let's leave the ancient technology of sticking tobacco powder on paper out of our conversation. A product with 80% paper is hard for us to call reconstituted tobacco.
Paper method and slurry method
The paper method and the slurry method are technologies from the last century. The past, which has exhausted itself. The processes are clear and studied. There is no need to expect great innovation from these methods. Because they cannot solve the fundamental tasks for efficient production: reducing the required amount of water, reducing energy costs for the removal of water from the suspension, reducing the harmful effects on the environment, complex control of moisture content and consistency of the final product.
The paper method and the slurry method had been producing results for decades because there was no alternative. The tobacco technologist did not need additional equipment on the cut rag tobacco line. Neither did they need additional manpower. All manipulation of reconstituted tobacco was the same as with natural tobacco leaf.
The paper method and the slurry method had been producing results for decades because there was no alternative. The tobacco technologist did not need additional equipment on the cut rag tobacco line. Neither did they need additional manpower. All manipulation of reconstituted tobacco was the same as with natural tobacco leaf.
Rolling process reconstituted tobacco
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Modern technology in the production of reconstituted tobacco.
Rolling process- A type of pressing process. When a tobacco sheet is formed under high pressure. Known by trade names such as nano fiber reconstituted tobacco, as well as the extrusion method (company in China).
Flexible, gentle, efficient and future-proof - these are the essential requirements for production plants in the tobacco industry. Making reconstituted tobacco by rolling is in line with the old motto. With one unfortunate little exception. Not the ability to pass DCC (Direct Condition Cylinder). In DCC such reconstituted tobacco disintegrates into small fragments. Such reconstituted tobacco needs to be handled with care.
Flexible, gentle, efficient and future-proof - these are the essential requirements for production plants in the tobacco industry. Making reconstituted tobacco by rolling is in line with the old motto. With one unfortunate little exception. Not the ability to pass DCC (Direct Condition Cylinder). In DCC such reconstituted tobacco disintegrates into small fragments. Such reconstituted tobacco needs to be handled with care.
We reinvented reconstituted tobacco
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We took the best of roll-out technology. Adding a new value - genuine strength. Our reconstituted tobacco is the first to be created using the roller-rolling method to pass the DCC.
- High strength characteristics are not empty wordsDo you load reconstituted tobacco bought from your supplier into the slicer or after DCC? If in the slicer and it's made by paper method or slurry, you're buying very expensive reconstituted tobacco.
- Less water is used - cheaper reconstituted tobacco.The old methods use huge amounts of water. Which must be evaporated during the drying process. These methods are not going to be cheap a priori.
- The uniqueness is in the simplicity of the idea.The difficulty is in the feasibility of the idea. Our technology does not have a very expensive process of producing nano fiber cellulose (cellulose nanofibers). Our product contains 90% tobacco and the smallest possible amount of adhesives. Our know-how: multi-stage rolling out with the correct friction of the rollers. Increased strength properties of reconstituted tobacco through mechanical action only. With minimum use of chemicals.
Environmental friendliness is the new requirement of the modern world.There are no protests under our windows by environmentalists over the dumping of wastewater into natural water bodies. This waste simply does not exist.
For you, the benefits are obvious. Significantly reducing the cost of producing cigarettes and making a big economic profit.
Maybe it's time for a new partnership?
We deliver top-quality reconstituted tobacco for various blends, ensuring cost savings and consistent quality.
- Russian Tobacco Factory is recognized worldwide as a reliable and efficient supplier of reconstituted tobacco. A large part of our business is focused on managing relationships with B2B companies.
- Reconstituted tobacco leaf plays an essential role in cigarette manufacturing. It can be produced from either the customer's byproducts or from specially sourced tobaccos.
- Additionally, we offer various standard reconstruired tobacco leaf (RTL) options such as Ready-to-Use, American Blend/Virginia, and Oriental/Burley. These options are available for immediate use. Or available for sale with a minimum wait time
- The Russian Tobacco Factory's RTL also provides significant cost advantages for blending. By combining reconstruired tobacco with virgin tobacco in various ratios, manufacturers can produce competitive cigarette products while controlling costs. This is particularly important in emerging markets, where maintaining a low price point is crucial for success and gaining market share in a competitive landscape focused on cigarette quality.
- Traditional methods of producing Reconstituted Tobacco Sheet involve a high glycerin-to-water ratio of up to 95% during processing. In contrast, our process yields tobacco material with a significantly lower moisture content of only 20 to 40%, resulting in quicker drying and a substantial reduction in nicotine and flavor loss. The Russian Tobacco Factory has also minimized binder usage in its production process, leading to higher tobacco content up to 90% and a decreased impact on flavor during combustion.
- We possess the expertise to produce high-quality reconstituted tobacco suitable for American blends and English/Canadian blends. These products can be incorporated into our existing blends and tailored for use in your blend as well. Furthermore, we can supply reconstituted tobacco in its original form, customized to meet your specific needs.
- The low moisture content of Reconstituted tobacco also positively affects environmental sustainability, as shorter drying times and reduced energy consumption lead to lower production costs compared to competitors.
- The tobacco slurry exhibits a solid consistency, unlike conventional Reconstituted 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 vital product attributes, such as nicotine content, within the desired range.
- We are closer than it seems. We have extensive experience in customs operations and the B2B tobacco business. We are friendly and invite you to visit. To see the bears playing the balalaika.
Reconstituted Tobacco: The Cost-Effective Alternative
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We see only one competitive product on the market - natural tobacco leaf.
All stages of primary tobacco processing (mixing, casing, cutting, dryer, cooling, flavoring, pneumatic transport) reconstituted tobacco passes without difficulty. Comparable to the behavior of tobacco strips. Comparison of our reconstituted tobacco and natural tobacco leaf:
- AffordabilityOur reconstituted tobacco is typically at least 50% less expensive than natural tobacco leaf. Although the exact price difference may fluctuate due to market conditions and variations in tobacco leaf types, it is not unusual for our reconstituted tobacco to be substantially more affordable than its natural counterpart. Having a 'cheaper' constituent in the blend with substitution rates of 10 to 20 percent and higher filling power than tobacco lamina drives better blend cost optimization.
- Reduced wasteBy incorporating our reconstituted tobacco leaf into the cut rag tobacco blend, cigarette machine waste can be decreased by up to 5%. The extent of waste reduction may differ based on the specific blend and manufacturing process, frequently leading to increased efficiency and lower overall production costs.
- ConsistencyOur reconstituted tobacco delivers greater uniformity in size, shape, and density compared to natural tobacco leaves. This consistency enhances the production process by minimizing the chance of machine jams or other complications that could generate waste.
- Enhanced property controlThe production process of reconstituted tobacco enables manufacturers to manage and fine-tune properties such as burn rate, moisture content, and density. These adjustments can contribute to a more streamlined cigarette-making process.
- Improved resistance to breakageReconstituted tobacco typically demonstrates greater resilience during secondary manufacturing processes, reducing the risk of breakage. The ingredients in the composition are carefully selected and also contribute to increased strength can help minimize waste.
- Process control and standardizationThe reconstituted tobacco manufacturing process allows for superior control over the properties and characteristics of the end product. This standardization can lead to more consistent quality and reduced secondary processing expenses.
- Economies of scaleLarge-scale production of reconstituted tobacco can be lucrative. As our reconstituted tobacco output expands, we can refine our manufacturing processes and lower costs, leading to decreased costs per unit of production.
Integrating reconstituted tobacco leaf into cut rag tobacco can result in reduced cigarette machine waste, fostering a more efficient production process and potential cost savings.
Maybe it's time to buy reconstituted tobacco instead of tobacco strips and start making money?
Optimal Utilization of Tobacco By-Products
Reconstituted tobacco leaf is an innovative technology in the realm of resource recovery within the tobacco industry. This technique is now extensively employed to produce contemporary blends in the sector. When stems are removed from tobacco leaves, the remaining weight of raw tobacco materials ranges between 68-78% of the initial amount. Around 22-32% of these losses can be attributed not only to moisture reduction, but also to by-products like stems, tobacco leaf particles, tobacco fines, and dust, which are unsuitable for use in their existing state. We reintroduce these leftover components of tobacco leaves, which would otherwise be discarded, back into the manufacturing process as a flexible material with a high-quality set of properties. This raw material can be combined with cut tobacco for cigarette production in a tobacco blend.
At this point, advancements in tobacco chemistry and technology enable us to generate a new class of reconstituted tobacco using the pressing method. This approach is not only more efficient but also yields a variety of high-quality, cost-effective reconstituted tobaccos that can be incorporated into blends and diverse types of cigarettes and cigars.
At this point, advancements in tobacco chemistry and technology enable us to generate a new class of reconstituted tobacco using the pressing method. This approach is not only more efficient but also yields a variety of high-quality, cost-effective reconstituted tobaccos that can be incorporated into blends and diverse types of cigarettes and cigars.
Benefits of Reconstituted Tobacco
Initially, reconstituted tobacco was employed by tobacco technologists for economic reasons as a cost-saving additive. Nowadays, it is a fundamental component of any American blend cigarette, as it enhances the product's physical, sensory, and chemical properties, as well as the smoke's chemical composition.
Contemporary advancements in reconstituted tobacco production technology enable us to create a product with specified characteristics, closely resembling natural tobacco and offering exceptional smoking properties.
The cost of raw tobacco in traditional supplier countries has been steadily increasing, along with the expansion of potential supplier locations. Cutting-edge tobacco reconstitution technologies have facilitated the development of balanced, high-quality, and cost-effective blends.
Depending on the by-products' type and properties, as well as the technology employed for reconstituted tobacco production, the tar content is 30-50% lower than in the original raw tobacco. For instance, tobacco by-products with an average resin content of 20 mg typically yield reconstituted tobacco with a resin content of around 10-15 mg.
In addition to reducing tar levels, using reconstituted tobacco plays a crucial role in decreasing 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 identical. The method we utilize, which is based on the latest advances in production organization and product development, enables us to produce various reconstituted tobacco types with desired properties.
Reconstituted Tobacco characteristics
• Sheet thickness: up to 0.25 mm
• Moisture content: 11.5-13.5%
• Shape: 10x10 cm sheets / thin-cut fibers 0.9 mm wide
• Nicotine content: 0.6-0.7%
• Carbohydrate content: 10-12%
• Chloride content: less than 1.0%
• Weight per square meter: 85-110 g
• Percentage of water-soluble substances by weight: at least 30%
• Color: ranges from light brown to dark brown
• Scent: distinct tobacco aroma
• Shelf life: 12 months
• Packaging type: C-48 corrugated box with a polyethylene liner
• Moisture content: 11.5-13.5%
• Shape: 10x10 cm sheets / thin-cut fibers 0.9 mm wide
• Nicotine content: 0.6-0.7%
• Carbohydrate content: 10-12%
• Chloride content: less than 1.0%
• Weight per square meter: 85-110 g
• Percentage of water-soluble substances by weight: at least 30%
• Color: ranges from light brown to dark brown
• Scent: distinct tobacco aroma
• Shelf life: 12 months
• Packaging type: C-48 corrugated box with a polyethylene liner
Reconstituted Tobacco characteristics
• Sheet thickness: up to 0.25 mm
• Moisture content: 11.5-13.5%
• Shape: 10x10 cm sheets / thin-cut fibers 0.9 mm wide
• Nicotine content: 0.6-0.7%
• Carbohydrate content: 10-12%
• Chloride content: less than 1.0%
• Weight per square meter: 85-110 g
• Percentage of water-soluble substances by weight: at least 30%
• Color: ranges from light brown to dark brown
• Scent: distinct tobacco aroma
• Shelf life: 12 months
• Packaging type: C-48 corrugated box with a polyethylene liner
• Moisture content: 11.5-13.5%
• Shape: 10x10 cm sheets / thin-cut fibers 0.9 mm wide
• Nicotine content: 0.6-0.7%
• Carbohydrate content: 10-12%
• Chloride content: less than 1.0%
• Weight per square meter: 85-110 g
• Percentage of water-soluble substances by weight: at least 30%
• Color: ranges from light brown to dark brown
• Scent: distinct tobacco aroma
• Shelf life: 12 months
• Packaging type: C-48 corrugated box with a polyethylene liner
Technological features
Savings on costly tobacco leaves contribute to the overall economic effect.
The production process for reconstituted tobacco was developed over 50 years ago for economic reasons, as a means to process by-products or parts of them by transforming them into a tobacco sheet that is more suitable for blending, processing, and cigarette manufacturing.
The ability to use both the classic form of reconstituted tobacco - in 10 x 10 cm sheets - and the thin-cut form with a width of 0.9 mm enables 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 tar and nicotine levels), and smoking properties (helping to preserve the overall bouquet of the composition).
At 20-25% of the total mixture, reconstituted tobacco can be considered part of the foundational blend, with the added benefit that its properties do not change over time. This is because reconstituted tobacco is less affected by the negative impact of growing conditions, market fluctuations, and other variables that influence the quality and cost of other tobacco varieties and categories within the foundational blend.
The outcomes of utilizing reconstituted tobacco produced with our technology are slightly different from the results of using natural tobacco during primary processing: blending, preparation, pre-saucing, cutting, drying, cooling, and final flavoring.
The outcomes of utilizing reconstituted tobacco produced with our technology are slightly different from the results of using natural tobacco during primary processing: blending, preparation, pre-saucing, cutting, drying, cooling, and final flavoring.
PRODUCTION METHOD
The automated process of creating reconstituted tobacco involves minimal operator intervention, who only oversee the production line elements' operation via specific devices at the technological control station.
The procedure commences with filling the dispenser (1) with tobacco by-products. These raw materials are fed into the dispenser using a pneumatic lift and thoroughly sifted to prevent clumping during subsequent moisture application.
Next, the material is transferred to the fine grinding mill (2). Following grinding, the crushed dry product is directed to the tobacco by-products calibration system (3). After passing through this system, it is channeled into the storage system (5a, 5b) using a pneumatic unloader (4). Simultaneously, the liquid component is prepared in the kitchen (7), where liquid additives such as propylene glycol and glycerin are combined with water and stored in reservoir tanks.
The dry and liquid components are blended in the mixing device (8). The dry component is supplied from the storage system through a dispenser (6), while the liquid ingredient comes from the kitchen. The dosage of each component is determined by the desired characteristics of the final product.
The procedure commences with filling the dispenser (1) with tobacco by-products. These raw materials are fed into the dispenser using a pneumatic lift and thoroughly sifted to prevent clumping during subsequent moisture application.
Next, the material is transferred to the fine grinding mill (2). Following grinding, the crushed dry product is directed to the tobacco by-products calibration system (3). After passing through this system, it is channeled into the storage system (5a, 5b) using a pneumatic unloader (4). Simultaneously, the liquid component is prepared in the kitchen (7), where liquid additives such as propylene glycol and glycerin are combined with water and stored in reservoir tanks.
The dry and liquid components are blended in the mixing device (8). The dry component is supplied from the storage system through a dispenser (6), while the liquid ingredient comes from the kitchen. The dosage of each component is determined by the desired characteristics of the final product.
The proportion of each component is determined by the desired characteristics of the final product. The resulting mixture is conveyed to a sheet forming machine (10) via a conveyor belt equipped with a metal detector (9). At this stage, the mixture is dried into a paste with a moisture content of 35-40%, which helps conserve energy during the drying phase by reducing the liquid content.
Using a spreader, the paste is uniformly applied to the belt, creating an even layer. The formed sheet is then transported to a multi-stage air-convection drying oven (11), which maintains a consistent temperature throughout its entire internal space.
After drying, the sheet is moved from the oven to a forming machine (13) using a belt conveyor (12). Here, the sheet takes on its final form as reconstituted tobacco, either as 10x10 cm sheets or as thin-cut fibers 0.9 mm wide, depending on the desired format of the final product.
The finished product is conveyed to the packaging and weighing station (15) using a conveyor belt (14). It is then packaged according to industry standards (C48 boxes with polyethylene liners) and prepared for shipment to the customer.
Using a spreader, the paste is uniformly applied to the belt, creating an even layer. The formed sheet is then transported to a multi-stage air-convection drying oven (11), which maintains a consistent temperature throughout its entire internal space.
After drying, the sheet is moved from the oven to a forming machine (13) using a belt conveyor (12). Here, the sheet takes on its final form as reconstituted tobacco, either as 10x10 cm sheets or as thin-cut fibers 0.9 mm wide, depending on the desired format of the final product.
The finished product is conveyed to the packaging and weighing station (15) using a conveyor belt (14). It is then packaged according to industry standards (C48 boxes with polyethylene liners) and prepared for shipment to the customer.
Would you be interested in receiving a sample of reconstituted tobacco or a quote?
Welcome to the future of tobacco!
Introducing reconstitution technology that creates an exceptional final product – Reconstituted Tobacco Leaf. This technology enables complete control over nicotine, sugar, and aroma parameters in tobacco blends. It offers high volumetric filling, low breakdown rates, and substantial economic advantages. Additionally, it ensures excellent aroma retention, particularly crucial for Burley and Oriental tobaccos.
Introducing reconstitution technology that creates an exceptional final product – Reconstituted Tobacco Leaf. This technology enables complete control over nicotine, sugar, and aroma parameters in tobacco blends. It offers high volumetric filling, low breakdown rates, and substantial economic advantages. Additionally, it ensures excellent aroma retention, particularly crucial for Burley and Oriental tobaccos.