Reconstruired tobacco leaf
The tobacco industry has long been a controversial topic due to the health risks associated with smoking. But, what has been overlooked is the potential of using recycled tobacco leaf (RTL) as an alternative to traditional cigarettes.
Reconstituted tobacco is a process in which tobacco waste is recycled and converted into a material that can be used as an ingredient in manufactured cigarettes. The recovery process involves treating tobacco waste with chemicals and then steaming them to give them a more uniform consistency. This process not only allows you to remove harmful toxins, but also helps to create a more homogeneous product that can be used in the production of cigarettes.
RTL has several advantages over traditional tobacco. This not only reduces the number of toxic substances in cigarettes, but also reduces the cost of their production. This is because the tobacco scrap used to make RTL is much cheaper than buying new leaves.
As for the health benefits, RTL has been shown to reduce the amount of tar and nicotine in cigarettes. This means that smokers who switch to RTL can enjoy a less harmful form of smoking without sacrificing the desired taste.
History
More than 50 years ago, a method was developed for producing reconstituted tobacco to processing tobacco by-products or parts thereof. The purpose of this process was to convert these by-products into tobacco leaf form, which was easier to work with in the cigarette manufacturing process. This method was developed for economic reasons to use all parts of the tobacco plant and reduce the amount of waste. This process was developed by the tobacco industry in the mid-20th century, and since then it has been a valuable tool for tobacco technologists.
Reconstituted tobacco is a valuable tool for the tobacco technologist
As the tobacco world continues to evolve, designers are always looking for new and innovative ways to stay ahead of the competition. One of such valuable tools is the use of reconstituted tobacco leaf making cigarettes.
Two types of reconstituted tobacco leaf
The tobacco industry can now choose between two forms of recon tobacco — classic 10 x 10 cm sheets and sliced 0.9 mm wide strips. The possibility of using both forms of reconstituted tobacco allows manufacturers to create customized and improved mixtures that meet market requirements.
Proper use of tobacco byproducts
Recovered tobacco leaf is a new technology in the tobacco industry, which involves the use of recoverable resources to create modern mixtures. After removing the stalks from the tobacco leaf, the weight of the raw material is reduced to 68-78% of its original weight. Losses in the amount of 22-32% are due to the loss of moisture, as well as by-products such as stems, tobacco leaf particles, tobacco fines, and dust, which cannot be used in their current form.
Instead of recycling these remediation residues, they are returned to the technological process in the form of a pliable material with high-quality characteristics. This raw material can be combined with chopped tobacco to produce a tobacco mixture for the production of cigarettes. Recent advances in tobacco chemistry and technology have made it possible to produce a new generation of reconstituted tobacco by pressing. This technology is not only more efficient, but also allows you to get a variety of varieties of high-quality and cheap reconstituted tobacco, which can be used in mixtures for various types of cigarettes and cigars.
Reconstruired tobacco leaf: Custom or Standard
The reconstructed sheet is available in both non-standard and standard versions, depending on the manufacturer’s requirements.
Custom-processed tobacco leaf is used in the production of premium brands, as there is great flexibility in the choice of shapes and sizes that can be created. This ensures greater creativity and individualization of the product. Standard reconstituted tobacco leaves are available in predefined shapes and sizes, which simplifies their use and eliminates any unnecessary waste during production.
Reconstituted tobacco can make up 20-25% of the total mixture and is considered part of the skeletal mixture. One of the significant advantages of using reconstituted tobacco is that its properties remain unchanged over time, unlike other varieties and categories of tobacco that are part of the skeletal mixture. Reconstituted tobacco is less susceptible to negative impacts, such as market fluctuations and growing conditions, which can affect the quality and cost of other types of tobacco.
Reconstituted tobacco manufacturing process
The production of reconstituted tobacco is an automated process in which operators control the elements of the production line only with the help of technological control devices. The process begins with loading tobacco by-products into a dispenser, where the material is sieved to prevent the formation of lumps before preheating to reduce the moisture content to 8%. The material then passes through a fine grinding mill and a calibration system before being sent to the storage system using a pneumatic unloaded. Meanwhile, the liquid components are prepared by mixing additives such as propylene glycol, glycerin, and water in storage tanks. Dry and liquid components are mixed in the device, and the dosage of each component depends on the characteristics of the final product. The resulting solution is transported via a conveyor belt to a sheet-forming machine, where it is dried to get a paste with a moisture content of 35-40%, reducing the amount of liquid to save energy. The paste is distributed using a spreader and transported to a multi-stage air-convection oven, where it is dried. The dried sheet is fed into a molding machine, where it acquires the desired shape either in the form of sheets or in the form of sliced fibers. Finally, the product is packaged and weighed according to industry standards before being shipped to the customer.
During the production of reconstituted tobacco, quality control measures are applied at various stages of the process. For example, tobacco by-products are selected to ensure the uniformity of the material and the absence of any impurities. Also, the mixing device is equipped with sensors that check the dosages of dry and liquid components to ensure that the correct proportions are used.
Once the recovered tobacco is packed, it is ready to be shipped to the customer. But, before it can be sold to consumers, it must first undergo rigorous testing to ensure that it meets industry quality and safety standards. This testing may include checking for moisture content, nicotine, and the presence of any harmful additives or pollutants.
IQOS product inspired by reconstituted tobacco
IQOS is a revolutionary product of Philip Morris International, which uses reconstituted tobacco instead of traditional cigarettes. This product has been designed to provide users with a better smoking experience without all the harmful effects associated with tobacco burning. IQOS is designed to heat rather than burn tobacco and releases a nicotine-containing aerosol that has been proven to be less harmful than cigarette smoke. The product uses a combination of dry and liquid components, including reconstituted tobacco, propylene glycol, and other additives. This allows the user to experience a subtle taste profile, different from traditional cigarettes, and at the same time receive a nicotine dose without harm to health.
The use of reconstituted tobacco in products such as IQOS is indicative of the tobacco industry’s desire to provide consumers with a more rewarding and enjoyable smoking experience. Since research shows that inhaling smoke from burning tobacco is harmful, the development of alternative products such as IQOS enables users to reduce exposure to toxins while enjoying the unique taste of tobacco.
In recent years, the tobacco industry has been paying more and more attention to health and safety issues. As a result, many companies have developed innovative products designed to reduce the potential harm associated with smoking. One such product is IQOS, which uses reconstituted tobacco to produce a nicotine-containing aerosol using only tobacco heating.
What is the future of reconstituted tobacco leaf?
The future of reconstituted tobacco leaf is an intriguing subject, one that is laden with the promise of reshaping the tobacco industry in ways before thought impossible. In the bygone eras, reconstituted tobacco leaf was leveraged to craft cigarettes that were easy on the pocket. But, the ceaseless evolution of the tobacco industry coupled with technological advancements has prompted manufacturers to look towards reconstituted tobacco leaf as a potential game-changer.
What makes reconstituted tobacco leaf stand out is its ability to produce a more uniform flavor profile while curtailing the number of hazardous toxins and carcinogens present in the final product. This factor has spurred manufacturers to explore fresh and innovative applications of reconstituted tobacco leaf, resulting in the development of avant-garde products like no-burn cigarettes and e-cigarettes.
The emergence of these novel products has ushered in a rekindled interest in reconstituted tobacco leaf, with manufacturers keen to innovate and introduce ever-more exceptional offerings that boast a superior flavor profile and minimal harmful components. The introduction of products such as IQOS and other no-burn cigarettes has expanded the horizons for manufacturers, enabling them to craft cigarettes that offer the taste and aroma of traditional cigarettes while reducing the presence of carcinogens and toxins. The reliable and cost-effective characteristics of reconstituted tobacco leaf make this feat possible, and the results are satisfactory.