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.