MANUFACTURING OF A C[Type text]

MANUFACTURING OF CIGARETTES

MANUFACTURING OF A CIGARETTE

CIGARETTES
Not all cigarettes are the same. Cigarette design is more complicated than it may seem. Foodtype ingredients and flavorings are added to some types of to balance the natural tobacco taste, replace sugars lost in curing, and give individual brands their characteristic flavour and aroma. Other ingredients control moisture, protect against microbial degradation, and act as binders or fillers .Nicotine is not added in making cigarettes. It occurs naturally in all varieties of tobacco plants. The filter, paper and level of filter ventilation are all chosen to affect the sensory strength and smoke yield of the cigarette. At each stage, there is constant quality control and testing. Main parts of a cigarette

Cigarettes have four basic components:

The tobacco rod The cigarette paper around the tobacco rod The filtration zone The filter and tipping around the filtration zone.

The tobacco in the rod includes tobacco lamina (the flat part of the tobacco leaf), tobacco stem (midribs of the leaf), and expanded lamina.

The cigarette paper includes paper and adhesive.

MANUFACTURING OF A CIGARETTE

The filter is made mainly from cellulose acetate fibers, known as tow. Cellulose acetate is derived from wood pulp. The fibers are bonded together with a hardening agent, triacetin plasticizer, which helps the filter to keep its shape. The filter is wrapped in paper and sealed with a line of adhesive. Sometimes charcoal is added to filters.

The tipping paper includes paper and adhesive.

PRODUCTION OF CIGARETTES:
Before going into the complete detail of manufacturing of a cigarette, there s a brief note of the site we has visited. PAKITAN TOBACCO COMPANY: Pakistan Tobacco Company Limited is part of British American Tobacco, the world's most international tobacco group, with brands sold in 180 markets around the world. Major products of the PTC AKURA are Capstan by palmer Local capstan(white) Gold leaf Gold flake Embassy

MANUFACTURING OF A CIGARETTE

Raw materials
Raw materials for Cigarettes Tobacco (leaves) 2year inventory Its a natural product thats why it is difficult to control it WMs (wrapping materials) Cigarette paper Filter Glue Ink (for the stamping of the brand)

Raw materials for packets Packing blanks Aluminum foil (placed inside) Inner frame (inner support) Cellophane (packing material) It is also use for outer packing of 10 or more cigarettes placed together TR (tear off strip ) Carton CBC (currogated board container )

Raw material for filter Acetate tow Glu Filter paper Plasticizer for strength

Structure of PTC industry AKORA

They have actually three main departments which work separately and then cigarette as a product is the result of the mutual work of the three. They are GLT Its stands for green leave thrashing Its role includes the purchasing of leaves from farmers Then it will do the thrashing of leaves, the process of separation of lamina of leaves from stem

MANUFACTURING OF A CIGARETTE

PMD It stands for primary manufacturing department. They have two separate lines for the leaves and stem, namely stem line and lamina line

STEM LINE / LAMINA LINE Function of PMD When processed tobacco leaf arrives at the factory, it is checked for quality and carefully blended with other ingredients that the brand recipe may call for, such as flavorings or expanded tobacco. They arrived in the form of bales of 215 kg. Here the moisture is usually 15%.the mixture is then pass through system of units namely Tobacco feeder Bale slicer Casing (3 in lamina line) Blending bin (5 in stem line ) KLK dryer CORE 12 (raw material or scrap has sand contents of less than 7% then its is useful,it contains 30%dust, 50%stem,20%%venol)

Keeping track of the various types of tobacco and blend components in use is key and computers are increasingly used to track production runs. Moisture content is also crucial. Too dry and the tobacco leaf will crumble; too moist and it may spoil during storage. The blended tobacco is treated with just the right amount of steam and water to make it supple and is then cut into the form used in cigarettes. Excess moisture is then removed so the cut tobacco can be given a final blending and quality check. Cut tobacco store is also a part of it

MANUFACTURING OF A CIGARETTE

SMD It stands for the secondary manufacturing department. Main machines present here are Cigarette making machine Packing machine/packer Case packer Filter making machines

Cigarette making machine MK-9 (Mark 9) It is used for the manufacture of a cigarette Total length of the cigarette is 83mm in which 61mm is the tobacco filled portion and the rest is the filter that is 22mm. Final raw material is inserted into it Suctioned and tobacco feeder works on it It has safety guard sensor which means that the machine eventually stops as one of its portion opens working Magnets are attached in it which eventually removes the metallic particles

MANUFACTURING OF A CIGARETTE

FUNCTION A steel band converts it into a beam shape form Glu and paper are covered on this beam A tobacco filled rod of at least 61mm is obtained from it which has been wrapped around by the filter paper. Actually first the rod of cigarette has a total length of 132 mm. Machine first converted into three separate pieces. Then each piece is further converted into two pieces.

Filter is then attached at the base of the rod with the filter assembler. On filter a layer of golden paper is wrapped around known as bobbin.

Machine then drops the centre loose end cigarettes into the base with the drop detector whereas filter miss use to detect the cigarettes with missing cigarettes. Then cigarettes then pass through the centrifuges

As a result we have the cigarettes in line having filter at one end and loose end at the other end.

MANUFACTURING OF A CIGARETTE

After that a tray is attached so that it stocks the cigarettes in case of the packer stops.

It has a capacity of producing 5000cigattes per minute

PACKER GDX2

It has a capacity of producing 400packets per minute In this machine packing blanks, aluminum foil, a inner frame, cellophane are a simultaneously introduced and they are packed into a box shape geometry After that TR tape and cellophane is also packed on the outside of the rectangular box Each pack of box contains 20 cigarettes Then these boxes are arranges in a pack of 20 cigarettes using cellophane.

MANUFACTURING OF A CIGARETTE

Case packer

In this machine the packs are placed into the carton using systems of hydraulics. These cartons then go to the finished goods store with the help of conveyor belt.

Setup of SMD One and a half maker, one packer, one case packer combined is known as one module. Total eight modules are working in the SMD In addition to this a separate France based machine 3D100 is presents which has a capacity of 1000 cigarettes per minute.

Filter maker KDF/ER

It is a separate machine used for the making of the filter. A large tow of 650 kg contains raw material of filter is inserted into it which is used for at least four and a half hours. It has a capacity of 4000 filters per minute. It does not have a conveyor and laborers are used for the transport of filters up to cigarette making machine.

Additional systems
Maintenance system (operational for whole week, one module a day) Engineering store

MANUFACTURING OF A CIGARETTE

Electrical section Recycling system None of the material or the resultant product is wasted but the whole of the system is recycled and then used again.