Factory’ production cycle comprises two major stages: tobacco treatment (Primary) and cigarette production (Secondary).

Production

The production plant of the company Donskoy Tabak is fully automated from tobacco treatment stage to packing finished products into cartons.

Tobacco treatment stage

It is the key stage of the manufacturing method applied in the Primary that includes processing of leaf tobacco, cutting and drying of tobacco as well as expanding stems.

Hi-tech computer-aided equipment from the German supplier HAUNI makes the tobacco blending process fully controlled according to set-up parameters.

Conditioning and casing

Leaf tobacco is fed into a conditioning cylinder where it becomes soft and elastic. Application of casings helps enhancing the taste of the tobaccos. Then, different tobacco types are stored in blending silos to mix them and spread moisture and casing over the whole tobacco bulk.

Cutting and drying cut tobacco

Blended leaf tobacco is conveyed to a feeder and then to tobacco cutting machines. A special scanner detects and separates foreign heavy bodies, string fragments and filaments. The cut tobacco is fed into an overheated air dryer. When drying (expansion effect), the filling power of the tobacco increases.

Tobacco stems and dust are separated

After that, the cut tobacco is cooled down to room temperature. Some additives are added to the cooled tobacco, following specific recipes.

Tobacco leaf stems almost do not contain nicotine and tar. Therefore, they are more suitable for manufacturing popular high quality light cigarettes.

Flavoring

Tobacco blend is fed to a flavoring cylinder where flavors are applied. Then, the flavored tobacco is fed into blending silos to be mixed homogeneously.

After some time, the cut tobacco is conveyed to a container filling station or to belt conveyor hoppers to be placed in cut tobacco stock. Then, the tobacco is delivered to the Secondary.

Storage

The cut tobacco, ready to convert into cigarettes, is placed in cut tobacco stock where a certain microclimate is maintained. The tobacco blend is delivered to the Secondary by a unique NEOTECHNIK feeding system fitted with pipelines for gentle tobacco transportation.

Secondary

The Secondary comprises of a filter cigarette production area, a filter rod production area and a non-tobacco material stock.

Filter rods

HAUNI and ITM machines are used to manufacture king size and super slim sized mono-acetate filter rods. The filter rods are shot to the cigarette makers by a pneumatic conveying system.

Productivity

  • HAUNI and G.D makers’ produce up to 11 thousand cigarettes/minute.
  • G.D, FOCKE and ITM packers’ produce is up to 550 packs/minute. The production lines are suitable to handle laminated blanks and polypropylene film with print.

The makers are equipped with weighing devices to control automatically tobacco weight in cigarettes, lasers for perforating tipping paper on-line to control tar and nicotine content in accordance with applicable norms. It is possible to produce cigarettes with recessed filters and to adjust cigarette parameters on-line.

Packing

The Cigarette production area comprises combined production lines for manufacturing cigarettes and packing them into consumer and transportation package.

Product quality control

An automated on-line quality estimation system keeps track of more than 65 quality parameters.

Testing laboratory is equipped with more than 55 up-to-date and high-precision instruments and devices.

The observance of rules and norms of industrial safety is one of the main priorities of the company Donskoy Tabak, and an essential of stable and economically effective development of the company. Providing healthy and safe working conditions is an integral part of the technological process. Employee life and health are the highest priority for the Company.

High quality of tobacco products

Are equally so most important goals of the company. All products must meet requirements of the Federal Law