“
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.
The global market for reconstituted tobacco sheet (RTS) continued to expand in 2021, despite the global crisis, increasing by $8 million. To cater to this growing market, an innovative and cost-effective product is required, which is exactly what the Russian Tobacco Factory is offering to all cigarette manufacturers.
Tobacco composite sheet is a versatile product in the tobacco market, originally designed to reintroduce costly stems and scrap tobacco into production. With the growing focus on tobacco control, the product gained an additional purpose - reducing nicotine and tar content. Reconstituted tobacco is commonly used as filler for cut rag tobacco and has various applications in the tobacco industry, such as substitutes for tobacco paper, cigarette paper, cigar wrappers, and binders.
Our tobacco sheet is a product of extensive lab work, resulting in enhanced strength and elasticity. Numerous tests by cigarette manufacturers have confirmed its high-quality standards. The tobacco sheet can successfully pass through the Direct Condition Cylinder (DCC) in the Primary Processing Line.
Our tobacco sheet is a product of extensive lab work, resulting in enhanced strength and elasticity. Numerous tests by cigarette manufacturers have confirmed its high-quality standards. The tobacco sheet can successfully pass through the Direct Condition Cylinder (DCC) in the Primary Processing Line.
“
The quality and affordability of the tobacco sheet begin with the well-planned design documentation for the plant.
Let's exclude the outdated technique of adhering tobacco powder to paper from our discussion. It's difficult for us to consider a product with 80% paper content as genuine recon tobacco sheet.
The paper and slurry methods are outdated technologies from the last century. These processes have been well-studied and exhausted, offering no room for significant innovation. They fail to address key challenges in efficient production, such as reducing water usage, lowering energy costs for water removal from suspensions, minimizing environmental impact, and effectively controlling the moisture content and consistency of the final product.
For decades, these methods were employed due to a lack of alternatives. Tobacco technologists didn't require additional equipment for the cut rag tobacco line or extra manpower. The handling of tobacco sheets was identical to that of natural tobacco leaves.
For decades, these methods were employed due to a lack of alternatives. Tobacco technologists didn't require additional equipment for the cut rag tobacco line or extra manpower. The handling of tobacco sheets was identical to that of natural tobacco leaves.
“
This is state-of-the-art technology in the production of tobacco sheets.
The rolling process is a type of pressing technique where a tobacco sheet is formed under high pressure. This method is also known as nano fiber tobacco sheets and the extrusion method. Flexible, gentle, efficient, and future-proof - these are the key requirements for production facilities in the tobacco industry. Producing tobacco sheets through the rolling process aligns with these principles, with one small drawback: the inability to pass the Direct Condition Cylinder (DCC). In the DCC, such tobacco sheets disintegrate into small fragments and therefore must be handled with care.
“
We have incorporated the best aspects of the roll-out technology while adding a new feature - true strength. Our tobacco sheets is the first of its kind to be created using the roller-rolling method and successfully processed in the DCC.
- High strength characteristics are more than just words.When using tobacco sheets from your supplier, do you load them into the slicer or after the DCC? If you load them into the slicer and they are produced using the paper or slurry method, you may be purchasing overly expensive tobacco sheets.
- Using less water results in more affordable tobacco sheets.Traditional methods require large quantities of water, which must be evaporated during the drying process. These methods inherently make the production process more expensive.
- The uniqueness of our approach lies in the simplicity of the concept, while the challenge is in its implementation.Our technology does not involve the costly process of producing nano fiber cellulose. Our product consists of 90% tobacco and the smallest possible amount of adhesives. Our proprietary technique involves multi-stage rolling with the proper friction of the rollers, increasing the strength properties of the tobacco sheets through mechanical action alone, while minimizing the use of chemicals.
- Eco-friendliness is a crucial requirement in today's world.Our production process does not lead to protests from environmentalists due to wastewater dumping into natural water bodies, as this waste is simply nonexistent.
The advantages for you are clear: significantly lowering the cost of cigarette production and generating substantial economic savings.
Could it be the perfect moment to establish a fresh collaboration?
- The Russian Tobacco Factory is a well-known and reliable provider of tobacco sheets, with a focus on building strong relationships with B2B companies. Offering tobacco sheets for sale all over the world.
- Tobacco sheeting services. Tobacco sheets are an essential component in the manufacture of cigarettes and can be produced from either the customer's byproducts or specially obtained tobaccos.
- We offer a range of standard tobacco sheets options, including Ready-to-Use, American Blend/Virginia, and Oriental/Burley, available for immediate use or with a minimal lead time.
- The Russian Tobacco Factory's RTS solutions offer cost savings in blending, allowing manufacturers to produce competitive cigarette products while keeping costs under control, especially in growing markets where maintaining low prices is crucial.
- Conventional tobacco sheet production methods often involve a high glycerin-to-water ratio of up to 95%, while our process results in a lower moisture content of 20 to 40%, leading to faster drying and reduced nicotine and flavor loss. We have also minimized the use of binders, increasing the tobacco content up to 90% and minimizing the impact on flavor during combustion.
- Our expertise enables us to produce high-quality tobacco sheets for American and English/Canadian blends, which can be incorporated into our existing blends or customized to meet your specific requirements.
- The low moisture content of our tobacco sheets also benefits the environment, as shorter drying times and reduced energy consumption result in lower production costs compared to competitors.
- Our tobacco slurry has a solid consistency, unlike traditional tobacco sheet production systems, making it easy to roll uniformly and control thickness with rollers. This consistency contributes to uniformity in subsequent processes and helps maintain vital product attributes, such as nicotine content, within the desired range.
- We are closer than you think, with extensive experience in customs operations and the B2B tobacco business. We welcome you to visit us and see the bears playing the balalaika.
Tobacco Sheets vs. Natural Leaves
“
The only rival product in the market that we recognize is natural tobacco leaves.
All stages of primary tobacco processing, including mixing, casing, cutting, drying, cooling, flavoring, and pneumatic transport, are effortlessly passed by our tobacco sheets, comparable to the behavior of tobacco strips. When comparing our tobacco sheets to natural tobacco leaves:
- AffordabilityOur tobacco sheets are often at least 50% cheaper than natural tobacco leaves, with fluctuations in the exact price difference due to market conditions and tobacco leaf variations. However, it is not uncommon for our tobacco sheets to be significantly more cost-effective. By incorporating our sheets into the cut rag tobacco blend with substitution rates of 10 to 20 percent and higher filling power, blend cost optimization is improved.
- Reduced WasteIncorporating our tobacco sheets into the cut rag tobacco blend can decrease cigarette machine waste by up to 5%. The extent of waste reduction may vary based on the specific blend and manufacturing process, often leading to improved efficiency and lower production costs.
- ConsistencyOur tobacco sheets provide greater uniformity in size, shape, and density compared to natural tobacco leaves, contributing to a more streamlined production process by minimizing the risk of machine jams or other complications that cause waste.
- Enhanced Property ControlThe production process of tobacco sheets enables manufacturers to manage and fine-tune properties such as burn rate, moisture content, and density, leading to a more efficient cigarette-making process.
- Improved Resistance to BreakageTobacco sheets generally demonstrate greater resilience during secondary manufacturing processes, reducing the risk of breakage. Carefully selected ingredients also contribute to increased strength and minimize waste.
- Process Control and StandardizationThe tobacco sheets manufacturing process allows for superior control over the properties and characteristics of the end product, resulting in more consistent quality and reduced secondary processing expenses.
- Economies of ScaleLarge-scale production of tobacco sheets can be economically beneficial. As our tobacco sheet output increases, we can refine our manufacturing processes and reduce costs, leading to lower costs per unit of production.
The integration of tobacco sheets into cut rag tobacco can lead to a decrease in cigarette machine waste, promoting a more efficient production process and the possibility of cost savings.
Perhaps it's time to consider switching to tobacco sheets instead of tobacco strips and start realizing financial benefits?
Appropriate Utilization of By-Products
Tobacco sheets is an innovative technology in the realm of recyclable resources within the tobacco industry. It is now extensively employed to create contemporary blends. After the stems are removed from tobacco leaves, the weight of the raw materials is reduced to 68-78% of their initial mass. The losses, accounting for about 22-32%, stem not only from moisture reduction but also from by-products such as stems, leaf particles, tobacco fines, and dust, which are unsuitable for use in their current state. We reintroduce these tobacco leaf by-products, which would otherwise be discarded and wasted, 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 in a blend for cigarette production.
At this stage, advancements in tobacco chemistry and technology enable us to produce a new generation of tobacco sheets using the pressing method. This more efficient technology generates various high-quality and cost-effective tobacco sheets types that can be incorporated into blends and used in different kinds of cigarettes.
At this stage, advancements in tobacco chemistry and technology enable us to produce a new generation of tobacco sheets using the pressing method. This more efficient technology generates various high-quality and cost-effective tobacco sheets types that can be incorporated into blends and used in different kinds of cigarettes.
Benefits of Tobacco Sheet
In the beginning, tobacco sheets were utilized by tobacco technologists for economic reasons as a cost-reducing additive. Nowadays, they are an essential component of any American blend cigarette, enhancing the product's physical and sensory properties as well as the smoke's chemical characteristics.
Current advances in tobacco sheet production technology enable us to create a product with specified qualities, closely resembling natural tobacco and providing excellent smoking properties.
As the cost of raw tobacco in traditional supplier countries continues to rise, along with the expansion of potential suppliers' geography, innovative 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 producing tobacco sheets, their tar content is 30-50% lower than that of the original raw tobacco. For instance, tobacco by-products containing an average of 20 mg of resin yield recon tobacco sheets with approximately 10-15 mg of resin.
In addition to reducing tar levels, the use of tobacco sheets plays a significant role in decreasing their carcinogenic activity. The biological activity of tobacco sheet smoke is roughly 70% lower than that of natural tobacco smoke.
Not all tobacco sheets are equal. Our method, which is based on the latest advances in production organization and product development, allows us to produce various tobacco sheet varieties with desired properties.
Тobacco Sheet characteristics
- Sheet thickness - no more than 0.25 mm
- Moisture - 11.5-13.5%
- Shape - sheets 10x10 cm / thin-cut fibers 0.9 mm wide
- Nicotine - 0.6-0.7%
- Carbohydrates - 10-12%
- Chlorides - less than 1.0%
- Weight of 1 m2 - 85-110 g
- Percentage of water-soluble substances by weight - not less than 30%
- Color - from light brown to dark brown
- Smell - pronounced tobacco
- Shelf life - 12 months
- Type of packaging - C-48 corrugated box with a polyethylene liner
Тobacco Sheet characteristics
- Sheet thickness - no more than 0.25 mm
- Moisture - 11.5-13.5%
- Shape - sheets 10x10 cm / thin-cut fibers 0.9 mm wide
- Nicotine - 0.6-0.7%
- Carbohydrates - 10-12%
- Chlorides - less than 1.0%
- Weight of 1 m2 - 85-110 g
- Percentage of water-soluble substances by weight - not less than 30%
- Color - from light brown to dark brown
- Smell - pronounced tobacco
- Shelf life - 12 months
- Type of packaging - C-48 corrugated box with a polyethylene liner
Technological Features:
Savings are achieved by using less expensive tobacco sheets instead of traditional tobacco leaves.
The process of producing tobacco sheets was developed over 50 years ago for economic reasons, as a method of processing by-products or part of them by converting them into a tobacco sheet that is more compatible with the processes involved in blending, processing, and cigarette manufacturing.
The option to use both the classic form of tobacco sheets (10x10 cm) and the thin-cut form with a width of 0.9 mm allows tobacco makers 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 (preserving the overall bouquet of the composition).
When used at 20-25% of the total mix, tobacco sheets can be considered part of the base blend, with the added advantage that their properties do not change over time. Tobacco sheets are much less influenced by the negative impact of growing conditions, market fluctuations, and other variables that affect the quality and cost of other tobacco varieties and categories that make up the base blend.
The results of using tobacco sheets produced with our technology are slightly different from the results of using natural tobacco in primary processing: blending, preparation, pre-saucing, cutting, drying, cooling, and final flavoring, as well as during cigarette production.
The results of using tobacco sheets produced with our technology are slightly different from the results of using natural tobacco in primary processing: blending, preparation, pre-saucing, cutting, drying, cooling, and final flavoring, as well as during cigarette production.
PRODUCTION METHOD
The process of producing tobacco sheets is automated, with operators primarily responsible for managing the production line elements through special devices at the technological control post.
The process starts by loading the dispenser (1) with tobacco by-products, which are fed into the dispenser using a pneumatic lift. The materials are thoroughly sifted to prevent clumping during subsequent moistening. To make grinding more efficient and conserve energy, the material is preheated in a heat sleeve, reducing its moisture content to no more than 8%.
Next, the material is sent to the fine grinding mill (2). Once ground, the crushed dry product is transferred to the calibration system of tobacco by-products (3). After passing through this system, it is moved 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, glycerin, and others are mixed with water and stored in reservoir tanks.
The dry and liquid components are combined in the mixing device (8). The dry component is fed from the storage system through a dispenser (6), while the liquid ingredient is delivered from the kitchen. The dosage of each component depends on the desired characteristics of the final tobacco sheet product.
The process starts by loading the dispenser (1) with tobacco by-products, which are fed into the dispenser using a pneumatic lift. The materials are thoroughly sifted to prevent clumping during subsequent moistening. To make grinding more efficient and conserve energy, the material is preheated in a heat sleeve, reducing its moisture content to no more than 8%.
Next, the material is sent to the fine grinding mill (2). Once ground, the crushed dry product is transferred to the calibration system of tobacco by-products (3). After passing through this system, it is moved 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, glycerin, and others are mixed with water and stored in reservoir tanks.
The dry and liquid components are combined in the mixing device (8). The dry component is fed from the storage system through a dispenser (6), while the liquid ingredient is delivered from the kitchen. The dosage of each component depends on the desired characteristics of the final tobacco sheet product.
The dosage of each component depends on the desired characteristics of the final tobacco sheet product.
Using a conveyor belt with a metal detector (9), the resulting mixture is transported to a sheet-forming machine (10). At this stage, the mixture is dried into a paste with a moisture content of 35-40%. This process aims to reduce the liquid amount, thus saving energy during the drying step.
With the help of a spreader, the paste is evenly applied to the belt, creating a uniform layer. The formed layer is then transported to the drying oven (11), which is a multi-stage air-convection oven that maintains a consistent temperature throughout its entire internal volume.
The dried layer is fed from the oven using a belt conveyor (12) into a forming machine (13). Here, it takes on its marketable appearance - tobacco sheets in 10x10 cm squares or thin-cut fibers 0.9 mm wide, depending on the desired format of the final product.
The finished tobacco sheets are sent to the packaging and weighing station (15) using a conveyor belt (14). There, they are packaged according to industry standards (C48 boxes with polyethylene liners) and prepared for further shipment to the client.
Using a conveyor belt with a metal detector (9), the resulting mixture is transported to a sheet-forming machine (10). At this stage, the mixture is dried into a paste with a moisture content of 35-40%. This process aims to reduce the liquid amount, thus saving energy during the drying step.
With the help of a spreader, the paste is evenly applied to the belt, creating a uniform layer. The formed layer is then transported to the drying oven (11), which is a multi-stage air-convection oven that maintains a consistent temperature throughout its entire internal volume.
The dried layer is fed from the oven using a belt conveyor (12) into a forming machine (13). Here, it takes on its marketable appearance - tobacco sheets in 10x10 cm squares or thin-cut fibers 0.9 mm wide, depending on the desired format of the final product.
The finished tobacco sheets are sent to the packaging and weighing station (15) using a conveyor belt (14). There, they are packaged according to industry standards (C48 boxes with polyethylene liners) and prepared for further shipment to the client.
Would you like to receive a sample of tobacco sheets or a price quote?
Welcome to the future of tobacco!
Reconstitution technology that produces an exceptional end product - Tobacco Sheets.
This technology enables you to have complete control over the parameters of nicotine, sugar, and the aroma of tobacco blends. It also provides high volumetric filling, low breakdown rates, and significant economic benefits, along with excellent aroma retention - which is especially important for Burley and Oriental tobaccos.
Reconstitution technology that produces an exceptional end product - Tobacco Sheets.
This technology enables you to have complete control over the parameters of nicotine, sugar, and the aroma of tobacco blends. It also provides high volumetric filling, low breakdown rates, and significant economic benefits, along with excellent aroma retention - which is especially important for Burley and Oriental tobaccos.