OUR QUALITY PRODUCTION PROCESS
(1) Raw tobacco
In our warehouse we currently stock tobaccos from 23 different countries. All our brands have their own specific tobacco recipe using a wide variety of raw tobacco (‘blends’). It all depends on the taste we are seeking to create.
As soon as we receive an order, the required raw tobaccos are sent from the warehouse. The still dry and pressed tobacco arrives in a rotating cylinder. The individual leaves are then moistened with water and steam to make them supple. Depending on the recipe, the tobacco is then refined with a mixture of liquorice, cocoa or sugar. In order to guarantee uniform moisture in the tobacco, the blend is then left to relax in a silo.
As the leaf fragments in the blend are still too large, the moist tobacco is passed through a special leaf cutter to produce fine strands, which are then perfect for use in cigarettes.
The still damp tobacco strands are passed through a dryer for further processing. Or into the ‘toaster’, as we like to call it. This gets rid of the excess water. This also makes for a more balanced, deeper and softer taste.
The final step consists of once again ensuring that the blend is well mixed. And, depending on the recipe, a further flavouring is added to the cut tobacco. This gives the cigarette a rounded flavour and is specific to each brand. Now the tobacco is ready for cigarette production.
The finished blend is moulded into a continuous strand of tobacco in the cigarette machine and wrapped with cigarette paper. The strand of tobacco is cut up into segments, which are the smokeable part of the cigarette. A filter is then added to each segment in the filter wrapping-paper machine. The cigarette is now ready to be smoked.
After the cigarettes have passed quality control, they are transferred to the packing machine. Here, a defined number of cigarettes are packaged in paper and the resulting packet is folded, glued and wrapped in cellophane in order to maintain freshness. 10 packets are placed in each carton, which are in turn packed for delivery. Now they are ready to be sent to the retailer.
Here the blend is everything.
A blend without additives or aromas.
Composed of three different tobaccos (Virginia, Burley and Orient) with 6% additives.
Mainly composed of Virginia tobacco, with 3% additives.
Mainly produced from sweet and mild Virginia tobaccos. This blend is mostly produced without additives.
‘Zware’ means ‘strong’ in Dutch and is mainly composed of fire-cured Kentucky, Latakia and air-cured Paraguay tobacco.
‘Half-zware’ means ‘medium strength’ in Dutch and is a combination of Virginia and Zware blends.
THE DIFFERENT TOBACCO VARIETIES
This blend is named after the US state where it was first cultivated. Due to the orange-yellow colour caused by hot-air drying, it is also known as ‘blond’ tobacco.
The Burley tobacco plant can grow up to 1.5m in height and is somewhat lighter than Virginia tobacco. Burley tobacco needs heavier ground and more fertiliser than Virginia tobacco.
Orient tobacco is the smallest and most resistant of the three plant varieties. As the name suggests, it fares especially well in hot regions, such as Turkey and the Middle East.
This dark tobacco is smoke dried. It therefore has a smoky
flavour and very characteristic aroma.
THE INS AND OUTS. WHAT YOU NEED TO KNOW.
These three terms are invariably voiced in the same breath when talking about tobacco products. So why? And what do they mean exactly? Here are the facts.
The constituents of smoke are defined through evaporation, as defined in EU or country-specific regulations. Tar, nicotine and carbon monoxide in cigarette smoke and fine-cut tobacco are measured against ISO and DIN standards.
The Landewyck laboratory is accredited to measure the constituents of smoke according to ISO 17025.
Not including the tobacco itself, all materials added to a tobacco product are defined as additives. Such as flavourings to achieve a rounded product, or material for the filter, paper or brand stamp.