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Green Leaf Threshing

How can the perfect products taste be achieved? Everything starts with the right blend of ingredients and its primary treatment. Obtain the best out of your products, in the most efficient way, with state-of-the-art machinery and seamless monitoring at every point in the production process.

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primary

Primary

How can the perfect tobacco products taste achieved? Everything starts from the primary treatment. With the right tobacco blend. With outstanding machinery and equipment at every point in the production process. With seamless monitoring and measurement of every stage and value.

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tobacco heated products

Tobacco Heated Products

Heated tobacco products represents a challenging evolution of tobacco business embraced by Garbuio. We support the customers with know-how and innovative ideas to process reconstituted tobacco for THP.

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digital solutions

Digital Solutions

Garbuio boosts the digitalization of Customer’s manufacturing systems and a broad concept of industrial Smart Factory, through a wide set of innovative digital solutions.

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Our expertise for your Primary processing

Solutions

Our expertise for your Primary processing

Green Leaf Threshing and the Primary are the start of a long journey. They are the first steps in the tobacco products manufacturing process. Here, the raw tobacco passes through a number of stages to prepare it for use in the cigarette makers and ensure the whole process runs smoothly. Garbuio is the global market leader in the development and manufacture of machinery and equipment for the Primary – mastering every step of the process and with a strong focus on quality.

PROCESSING - Well equipped at every station

Slicing

A clear cut

The leaves have spent two years packed tightly together, separation is a delicate process. In the first step, the slicer cuts the raw tobacco bales into smaller portions. This prepares them for the next stage – tobacco conditioning.

 

The leaves have spent two years packed tightly together, separation is a delicate process. In the first step, the slicer cuts the raw tobacco bales into smaller portions. This prepares them for the next stage – tobacco conditioning.

 

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Loosening and Conditioning

The soft processing

<p>Tobacco conditioning lay the foundations for a consistently high level of cigarette quality and ensure that downstream production processes run like clockwork. In the conditioning cylinder, the dry raw tobacco is loosened...

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Tobacco conditioning lay the foundations for a consistently high level of cigarette quality and ensure that downstream production processes run like clockwork. In the conditioning cylinder, the dry raw tobacco is loosened using water and steam. This opens the pores of the individual tobacco leaves, to get ready for the next step.

 

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NTRM removal

The search for hidden particles

<p>They may be tiny – but the smallest particles of non-tobacco related material can spoil the appearance and taste of a cigarette. A series of systems now inspect, detect, and remove unwanted material from the tobacco. These...

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They may be tiny – but the smallest particles of non-tobacco related material can spoil the appearance and taste of a cigarette. A series of systems now inspect, detect, and remove unwanted material from the tobacco. These include magnets, screen belt conveyors, separators, metal detectors, and sophisticated optical detection systems. They ensure that only the tobacco remains.

 

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Casing

Smells and tastes good

<p>At this stage of the process, the leaves are sprayed with additives and humectants in the casing cylinder. Here, the casing is sprayed onto the pre-warmed tobacco. It is important that casing is always applied to warm...

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At this stage of the process, the leaves are sprayed with additives and humectants in the casing cylinder. Here, the casing is sprayed onto the pre-warmed tobacco. It is important that casing is always applied to warm tobacco as this enables it to penetrate the pores in the leaf surface and absorb consistently. The casing is a sugary liquid containing a variety of humectants and flavorings, e.g. glycerine and extracts of liquorice, chocolate, plums and figs.

 

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Flattening

Flat as a flounder

<p>Tobacco leaves also contain stems. These are low in nicotine and sugar and thus in great demand for use in light, low-nicotine cigarettes. They have high filling power and are therefore suitable in cigarette production. When...

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Tobacco leaves also contain stems. These are low in nicotine and sugar and thus in great demand for use in light, low-nicotine cigarettes. They have high filling power and are therefore suitable in cigarette production. When the stems are flattened, the structure of the expanded fibres can be enhanced. In other words, the cigarette makers can process the stems more effectively and the quality of the cigarette also improves.

 

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Cutting

Razor sharp

<p>Once the tobacco leaves have been blended to perfection, they go under the knife. The cutting tools must always be kept clean and extremely sharp because this has a significant impact on the quality of the final blend. But...

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Once the tobacco leaves have been blended to perfection, they go under the knife. The cutting tools must always be kept clean and extremely sharp because this has a significant impact on the quality of the final blend. But perfectly honed blades also increase precision and produce less dust. Tobacco cutters which automatically sharpen the knives according to their level of wear are a vital part of the product portfolio. They can process up to 12 tons of fine cut tobacco leaf and three tons of leaf stem per hour.

 

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Expansion

May we expand a little?

<p>The tobacco is now rapidly heated to a temperature above the boiling point of water. Steam condenses on the tobacco, forcing up its temperature. The rapid temperature rise causes the water in the tobacco cells to expand....

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The tobacco is now rapidly heated to a temperature above the boiling point of water. Steam condenses on the tobacco, forcing up its temperature. The rapid temperature rise causes the water in the tobacco cells to expand. This increases the volume of the tobacco and gives it higher filling power. The tobacco now passes into the dryer.

 

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Drying

Fast drying

Immediately after being expanded, the tobacco is dried in a jet of steam heated to 300°C in a low-oxygen environment. This fast process dries the tobacco gently and fully preserves the cell expansion generated in the previous step.

 

Immediately after being expanded, the tobacco is dried in a jet of steam heated to 300°C in a low-oxygen environment. This fast process dries the tobacco gently and fully preserves the cell expansion generated in the previous step.

 

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Cooling

Cooling prevents collapse

<p>After drying, the tobacco is cooled. Why is that important? Firstly, because rapid cooling helps to stabilize the filling power gains achieved in the dryer. Secondly, because the dried tobacco must be cold when it enters the...

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After drying, the tobacco is cooled. Why is that important? Firstly, because rapid cooling helps to stabilize the filling power gains achieved in the dryer. Secondly, because the dried tobacco must be cold when it enters the flavor cylinder. This is the only way to ensure full preservation of aroma.

 

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Flavoring

A final touch of flavor

<p>The final step of tobacco processing. Flavorings are evenly sprayed onto the cut tobacco. They create the unmistakable scent of a freshly opened packet of cigarettes and give the cut filling material its characteristic...

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The final step of tobacco processing. Flavorings are evenly sprayed onto the cut tobacco. They create the unmistakable scent of a freshly opened packet of cigarettes and give the cut filling material its characteristic flavor. The product is gently mixed during processing.

 

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LOGISTICS - In the right place at the right time

Unpacking

Hand over the tobacco

<p>Before the next stage can begin, the tobacco has to be unpacked. The tobacco leaves are generally shipped to cigarette factories in 200 kg cartons or bales. So the first job is to remove the packaging. The unpacking station...

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Before the next stage can begin, the tobacco has to be unpacked. The tobacco leaves are generally shipped to cigarette factories in 200 kg cartons or bales. So the first job is to remove the packaging. The unpacking station is fast, reliable, and flexible. It is capable of unpacking up to 60 cartons per hour – that’s around 12,000 kg of tobacco. The machine requires extremely little maintenance and can easily be converted for different carton designs.

 

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Box Filling

Always stay flexible

Filling stations are vital for achieving maximum flexibility in the scheduling of cigarettes production. Here, containers and cartons are carefully filled with cut tobacco. Tobacco can be poured out for production as required.

 

Filling stations are vital for achieving maximum flexibility in the scheduling of cigarettes production. Here, containers and cartons are carefully filled with cut tobacco. Tobacco can be poured out for production as required.

 

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Maker Feeding

The perfect feed

<p>An abundance of tobacco – the blends are ready for processing. A variety of tobacco feed plants ensure a reliable supply of tobacco to the cigarette makers. Box tippers, gantry robots and mini-silos are integrated in a fully...

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An abundance of tobacco – the blends are ready for processing. A variety of tobacco feed plants ensure a reliable supply of tobacco to the cigarette makers. Box tippers, gantry robots and mini-silos are integrated in a fully automated logistics & storage area. These are directly connected to the Secondary. Tobacco is pneumatically transported through long pipelines from the feeder to the maker. The plants guarantee a smooth and gentle feed. The transport capacity and air speed can be precisely and automatically adjusted and controlled.

 

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Weighing

Dynamic monitoring

<p>Billions of cigarettes – all with the same tobacco quality and high level of consistency. That takes a lot of work. The tobacco mass flow therefore requires precise monitoring and metering in the Primary. This is the task of...

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Billions of cigarettes – all with the same tobacco quality and high level of consistency. That takes a lot of work. The tobacco mass flow therefore requires precise monitoring and metering in the Primary. This is the task of dynamic weigh belts.

 

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Storage and Blending

The safe place

<p>Careful blending of the tobacco is essential. This is the only way to create homogeneous and consistent blends, which ultimately decide the quality of a cigarette and give them their unmistakable taste. Blending silos create...

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Careful blending of the tobacco is essential. This is the only way to create homogeneous and consistent blends, which ultimately decide the quality of a cigarette and give them their unmistakable taste. Blending silos create the perfect tobacco blends and can also be used as storage and buffers.

 

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Separation

Gentle separation

<p>This step removes larger particles, such as leaf stems, from the production flow. It increases the overall efficiency of the removal of unwanted stems from the cut tobacco. Fewer particles also mean fewer irregularities in...

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This step removes larger particles, such as leaf stems, from the production flow. It increases the overall efficiency of the removal of unwanted stems from the cut tobacco. Fewer particles also mean fewer irregularities in formation of the tobacco rod during the cigarette manufacturing process. And fewer embers falling from the cigarette during smoking.

 

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Pneumatics

Dust removal

<p>The preparation and finishing of tobacco is, to say the least, a dusty job. Dust extraction systems are required at various stations in the Primary. We support our customers with effective air-flow dust filters and cyclones....

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The preparation and finishing of tobacco is, to say the least, a dusty job. Dust extraction systems are required at various stations in the Primary. We support our customers with effective air-flow dust filters and cyclones. Air-flow dust filters separate the dust while cyclones remove solid bodies from the air. Both are then collected and, if necessary, re-used. From the removal of the packaging to the tobacco transport – we guarantee clean air in the Primary.

 

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