Cigarette Production Technology

Yesmoke is the first to compete with the cigarette producing cartel in their own ballpark…

…with a product that is technically perfect, as a premium product must be, and therefore produced with the most advanced technology available on the market.

Annual production capacity: 10 billion cigarettes (500 million packs of 20 cigarettes, 1,000 40-ft. containers).

Primary “Garbuio” – The Tobacco Treatment Line Process

After the tobacco is stored and aged, it goes through a final processing phase according to blend formulas used for making various types of cigarettes. This process includes slicing, conditioning, casing, cutting, drying and top flavoring. Once this is done, the raw material is finally ready to be made into cigarettes.

The Tobacco Slicer

This first part of the machine slices the bales of tobacco with a vertical blade using the weight of the bales to speed up the cutting and separation inside the conditioning cylinder. These slices are carried on a conveyor belt to the DCCC (conditioning and tanning cylinder).

The DCCC – Conditioning and Tanning Cylinder

This is the tobacco conditioning and tanning cylinder. The slices coming from the Tobacco Slicer are transported into the cylinder on a vibrating belt that loosens the tobacco. In the DCCC, it is further broken up, humidified with steam and tanned with the aroma casing without degrading the tobacco.

The Silos

This section of the production line is used to further mix the tobacco coming from the DCCC and allow it to rest; it is loaded with a special mobile trolley. The humidity and aroma of the tobacco mix is homogenized during this rest period in the Silos.

The Tobacco Cutter

This machine shreds the tobacco coming from the Silos. The mix is poured into the compacting device, which is generally a deep tray. Sensors that ensure the correct quantities measure the levels of tobacco mix, the mix is then compacted by a special belt and chopped up with five knives fitted onto a rotating drum.

The Tobacco Dryer

This section of the tobacco treatment line is needed to dry the still damp tobacco coming from the shredder. The mix is dried with the combined action of heated air that passes through the cylinder and steam batteries that make up the cylinder surface.

The Tobacco Dust Aspirator

This component of the line does not work directly on the tobacco. It is an air exhaust unit fitted with a filter that collects the dust created along the Primary line after the tobacco mix has been dried. The dust is collected in containers and later appropriately disposed off.

The Mini Feeder/Stems Line

This machine adds expanded stems to the previously cutted and dried tobacco. The stems are stored inside a Mini-Feeder with a dumper and from here, they are automatically dosed into the mix. A special device installed under the belt controls this operation.

The Flavour Cylinder

This machine is used to improve the tobacco flavour by adding aromas. The tobacco mix passes through a rotating cylinder where it is sprayed with aromas. Thanks to the mechanical action of the paddle blades fitted on the inside surface of the drum, and the highly efficient action of the numerous nozzles, completely controlled by the automation system, the aroma addition process is very homogeneous.

The Treated Tobacco Silos

This is the terminal part of the Primary line. It consists of four silos set side by side where the tobacco is allowed to settle to improve the quality. From here, it will be picked up by an automatic aspiration system and sent on to the cigarette production lines.

Secondary – Cigarette making and packaging processes

After completing the preparation and conditioning process, the tobacco is ready for the cigarette. We have arrived at the phase called “Secondary;” it consists in the manufacture of the actual cigarette, followed by the packaging of the 20 cigarettes, of the cartons with 200 cigarettes and the cases containing 50 cartons.

The Cigarette Makers – G.D 121/AF12

The G.D Cigarette Maker Line can produce up to 10,000 cigarettes per minute. The shredded tobacco arrives from the treated tobacco silos (in 121) and is automatically sorted by a first part of the machine that separates any elements not suitable for production. The resulting material is shaped into two small, continuous, twin cylinders of cut tobacco with paper around it; these “worms” are continuously fed into the next machine, the AF12. The AF12 Filter Adder picks up the filter cylinders coming from the Molins PM5, cuts them to size and glues them to the tobacco cylinders coming from the 121. The finished cigarette is made. The last operation is the cigarette ventilation that is done by perforating the filter with a ROFIN laser. It is important to note that this entire production procedure is completely automatic; there are no line stops, as even the paper reel is changed without interrupting the production process.

The Cigarette Buffers – G.D B21

The B21 is a cigarette/filter buffer of the FIFO (first-in, first-out) type, capable of guaranteeing total product traceability. It can be used as a buffer both for directl maker-packer linkups in a cigarette production line, and as a buffer in a filter production line. The cigarettes coming from the cigarette maker are stored in a buffer. When the buffer is full, the packaging machines gradually empty it.

The Hinge-Lid Cigarette Packers – G.D X3

The X3 hinge-lid packer is an evolution of the X2 model. The G.D X3 Hinge-Lid Packer is the machine that fits the cigarettes into the packs. Completely automatically, it picks up the cigarettes from the G.D B21 Cigarette Buffer and with a set of wheels makes up the pack of cigarettes that only has to be cellophane wrapped.

The Cigarette Packs Cellophane Wrappers – G.D C600Pack-OW

The C600/Pack-OW wraps the packs of cigarettes coming from the G.D X3 with polypropylene; it also adds the government stamp and the little red opening strap taken from a reel. The cellophane-wrapped packs are then divided into groups of 10 and sent to the carton former at the end of the line. The finished cartons of 100 cigarettes are then sent to the cardboard box packager.

The Cigarette Cardboard Box Packagers – Senzani SBNE

The Senzani SBNE is an automatic vertical cardboard box packager with a very compact layout and with the box output on the upper level. The box packager receives the cartons of cigarettes from the G.D line and forms two stacks of cartons that are pushed into the cardboard box until it is full. The filled box is closed with high temperature gluing and then sealed with tape.

Secondary – Cigarette filter making and distribution system processes

Making the filters, using the latest technologies, is the pride and joy of Yesmoke’s production process. The filter is an extremely important and delicate element, because it determines the optimum balance of the cigarette; its production is subjected to constant inspections and quality controls by our laboratory technicians.

The Cigarette Filter Rod Manufacturing – Molins PM5/TO6E & FlexLink filter buffer

The PM5E/TO6E is an integrated tow opening and plug making combination for the production of cellulose acetate filter rods. The TO6E will handle all current types of cellulose acetate and liquid plasticizer, with all controls in easy access while the roll area is safely guarded with transparent covers. After they have been produced, the filters end up in the FlexLink filter buffer located above the two Molins lines; from here, they are conveyed by belts towards the Pegasus 3000s, which distribute them to the cigarette-making machinery.

The Cigarette Filter Distribution Systems – Molins Pegasus 3000

The MOLINS PEGASUS 3000 is a system for distributing the filters. The filters come from the MOLINS PM5E-TO6E are shot with compressed air through a plant towards the makers. The system is entirely modular. Each distribution module is completely self-contained with its own separate motor drive, air supply and control system and in a manufacturing environment modules can be added or subtracted with minimal disruption to production.

Warehouse of finished product

The cases are sent to the warehouse on a conveyor belt. There a robot forms the pallets and keeps everything in order – all completely automatically.

The Cigarette Master Cases Palletizing Robot – ABB IRB 660/FlexLink

This is a speedy machine that combines a 3.15 meter reach with a 180 kg payload. A robot picks up the cardboard boxes that contain the cartons coming from the production line and places them on pallets that then pass on to successive procedures. The palleting design and assembly system were developed by FlexLink.

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