High Expansion Process

Tobacco machinery sales

Expanded Shredded Stem (ESS)

Garbuio is the only company with the license to commercially exploit the ESS process which was originated by RJR Tobacco.

Reducing Blend Costs While Improving Quality
ESS consists of a front-end with conventional feed and handling equipment, the special ESS equipment itself, and final product handling and storage.
The front end can in many cases be shared with conventional stem line equipment and incorporates blending and heavies / metal rejection.

The ESS expander is the heart of the process and is subject to confidentiality regarding know-how of its design and operation. Following the expansion process there are additional process steps which establish the desired particle size distribution and moisture content.

The ESS process removes a significant quantity of volatiles from the product and this is discharged in the exhaust from the expander. Garbuio can offer a thermal oxidiser and waste heat boiler to provide an energy-efficient solution, thus effectively treating the exhaust and generating the entire process steam requirement using waste heat from the thermal oxidiser.

ESS product characteristics give the cigarette designer new and exciting possibilities to improve quality, lower deliveries and reduce blend costs.

Dry Ice Expanded Tobacco (DIET)

Garbuio have been associated with the DIET process since the 1980’s, and have worked together with Toromont Energy Systems and their predecessors to implement many successful DIET projects worldwide.

Highest Possible Lamina Expansion
The DIET process comprises two main areas of equipment and expertise: the ‘cold end’ or CO2 handling systems which is Toromont’s expertise, and the ‘Hot end’ or tobacco expansion and drying which is Garbuio’s.

Cut tobacco from a conventional primary process is fed to the CO2 impregnation system in precisely weighed sub-batches, and impregnated with liquid CO2 at pressures of 30 - 35 Bar. The impregnators are filled with liquid CO2 before being drained, depressurised and the residual gaseous CO2 removed and recovered by re-compression.

The frozen tobacco is now discharged from the impregnators, and passes through special opening doffers to a buffer silo. It is then fed at a controlled mass flow by means of a special low-temperature Weycon to the infeed of a specially designed air dryer in which the frozen tobacco is subject to a process gas stream consisting mainly of superheated steam. This causes the ‘dry ice’ or solid CO2 contained within the tobacco cellular matrix to change state from the solid to the gaseous phase (sublimation). Due to the fact that the volume of gaseous CO2 is vastly greater than the volume of dry ice, the tobacco is expanded, in some cases to double its original volume depending on the nature of the tobacco.

Following expansion, the product moisture is corrected to the desired final value if necessary, and unwanted heavy items (e.g. stems and other contaminants) removed by classification in an Elutriator (see other web page for more details of this product).

The DIET material may then be filled into bins or boxes for onward storage and transportation, or may be conveyed to silos ready for Addback in the Primary process.

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Expanded Shredded Stem (ESS)

  • Natural blend component
  • Mixes well with other blend components
  • Runs well on cigarette maker
  • Neutral taste
  • Dilutes flavour and tar / nicotine deliveries
  • Reduces blend cost
  • Fill value similar to DIET
  • Improves/ maintains cigarette quality
  • Allows recovery of waste materials (winnows, knock-outs, fibres)
  • Enhances taste of Burley stem, eliminates harshness

Dry Ice Expanded Tobacco (DIET)

  • Established high expansion process for cut lamina
  • Reduces Tar and Nicotine in cigarettes
  • High fill value
  • Ameliorates taste of certain tobaccos