THE (ALMOST) PERFECT CIGAR PRODUCTION LINE – Decouflé and Hauni teamed up to achieve this ambitious goal. The solution was developed as a cooperation between several companies in the Hauni Group and delivers both flexibility and efficiency.
Decouflé’s motto "Your business is unique – so are our solutions" clearly positions Hauni’s French subsidiary as a provider of tailor-made products and services in the tobacco market. The challenge from its customer was clear: design a new cigar maker that is capable of manufacturing three different products on the same line.
It certainly sounded like a job for Decouflé – and its partners in the Hauni Group. Sodim and Borgwaldt contributed their know-how in the field of measurement technology and Borgwaldt Flavor its expertise in flavors, while Hauni supplied the special subassemblies and logistics. "Team work was the most important factor in the success of our project," says Arnaud Masson, Project Manager at Decouflé. Its success is underlined by some remarkable statistics: during the official final acceptance by the customer, the revised and upgraded cigar line completed a perfect, non-stop run of eight hours with an efficiency of 99.92 percent.
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Extensive to-do list
In addition to the "three-product requirement", the developers’ to-do list contained further challenges. The time required for product format changes – the line produces cigars with and without shaped heads, or with a shaped head of a different diameter – should be approx. five hours. And conversion to other tobacco varieties should be completed in just two hours. Moreover, it should be capable of making up to 1,200 cigars per minute and feature integrated weight control and flavor spraying functions. The design specifications also included an automatic tray filling function and a more compact overall footprint. The special challenges of the project were quick to emerge: the different properties of the threshed tobacco – sometimes with, sometimes without flavor – and the recon binders used instead of paper. The special formats, which differ greatly from those of standard cigarettes or cigarillos, required a high level of attention from everyone involved in the project.