Cigarettes manufacturing process

The procedure begins with the creation of a single long cigarette known as a “rod.” A spool of cigarette paper with a length of up to 7,000 meters is unrolled and a line of tobacco is placed on it to make the rod. The tobacco is then wrapped in cigarette paper to produce the rod.

Filters are inserted at both ends of the super-sized rod while it is cut into shorter pieces by machines. The filters are then connected with “tipping paper,” which is the paper that wraps around the cigarette’s filter tip. After that, each shorter rod is sliced in half, resulting in two filtered cigarettes. Each cigarette is inspected at three separate stages to ensure that it is of high quality.

Primary process

Many people contribute with passion and commitment to each step of the process, from the moment the tobacco leaf is collected in the field until it is changed into a sting and inserted into the cigarette so that the end result is the creation of an excellent quality product.

The primary process is defined by the development of blends, which is nothing more than the enhancement, homogenization, and combining of various tobaccos. They are fragmented by guillotine cutting, and during the production cycle in the various lines, they are subjected to various temperature and humidity treatments, as well as by-product additions that enrich the various blends, depending on the brand of cigarettes to be manufactured.

The result of this procedure is determined by the quality of the thread that makes up the cigarette bar, which operators and mechanics with extensive knowledge manage to give it the seal quality that identifies us since we have the best tobacco leaves in the world.

Secondary process

Cigar manufacture is now an almost fully automated operation. In the so-called secondary process, tobacco fibers, cigarettes paper, and filters are continuously fed into the cigarettes machines.

Several aspects of the cigarette are measured along the production line to ensure that it is of the highest quality. Circumference, pressure drop, ventilation, stiffness, paper permeability, humidity, and loss through the tips are only a few of them.

The marked goods are then wrapped in a protective film and grouped in cartons and boxes in the packing machines. Additional checks are carried out at this point to ensure that the cigarettes are safe.

In addition, the package closing is measured to verify that the proper humidity content is maintained. The visual inspection of the carton, package, and cigarettes ensures that the consumer will receive a product that meets the quality criteria.

Brascuba maintains constant monitoring in accordance with the product’s requirements, taking into account the regulations in effect in each market. All of these procedures are inextricably tied to Occupational Health and Safety standards.

According to the International Organization of Standardization rules, the concentration of tar, nicotine, and carbon monoxide in cigarette smoke is measured in a smoking machine (ISO).

Putting together the last pack

To maintain freshness, individual cigarettes are separated into pack-sized groups and wrapped in foil.

The cigarettes are encased in the pack itself. The finished pack is then covered in a protective film that also helps to retain the aroma and freshness of the cigarettes. For shipping, the packs are packed in cartons or wrapped and placed in a master case.

Although cigarette manufacturing is a highly automated operation, it nevertheless necessitates close monitoring by our factory staff. Machines should never be trusted with leaf inspection, blending, or final product quality assurance.