- Intelligent, integrated solutions
- Machinery & process equipment | Körber
- Reconstituted tobacco processing
Reconstituted tobacco processing
Maximize yield, reduce costs, and enter the HTP market with our tobacco dust amalgamation (TDA) solution for reconstituted tobacco.
Convert tobacco, tobacco dust and fines into high-quality cut rags, cigar wrappers, or HTP sticks.
Benefits
Superior sustainability
The TDA process uses 15 times less water and 10-15 times less energy than competitor solutions, lowering your environmental footprint.
Enhanced taste & nicotine
Gentle processing retains more flavor and nicotine compared to cast sheet methods. And the resulting dough dries faster and has fewer binders.
Lowest operational costs
Benefit from the lowest investment and production costs per kilogram in the industry.
Integrated ecosystem
Our solutions work seamlessly with your machinery and process systems—ensuring flavoring is integrated into production environments.
Quality standardization & consistency
Reconstituted tobacco offers highly uniform physical properties, stable burning and draw characteristics, compared to natural leaf material.
Unparalleled expertise
We have 80 years of experience in the tobacco business and are the number one machine supplier in the industry.
Convert waste into value
Our solution converts zero-value by-products—dust and fines—into high-quality reconstituted tobacco.
Manage cost volatility
Replace expensive, variable-quality leaf with reconstituted tobacco, and protect yourself from crop quality fluctuations.
Ensure regulatory compliance
Our reproducible dosing and traceability processes simplify your compliance protocols.
Entering the HTP market
Our TDA line offers a scalable, low-barrier entry point into this growing reduced risk product (RRP) category.
In numbers
Speed
1,000 kg/h
Processing speed of 1,000 kg/h and 2,000 hours per year.
Water reduction
6M
The TDA method saves over six million litres of water compared to slurry or cast-leaf method.
Energy savings
4M
Save 4 million kilowatt hours of energy every year compared to using slurry.
Water content
30%
Our TDA blend contains 30 percent water, instead of the usual 80 percent.
Features
Control & consistency
Use cases for TDA reconstituted tobacco
- Leaves: Add-back for tobacco, hemp, clove cigarettes
- Bobbins: HTP sticks
- Bobbin: Cigar wrapping
Innovation
See how our TDA pilot plant enables you to test recipes and produce mini batches of reconstituted tobacco for cigarettes, cigars, and HTP applications.
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A holistic approach to recon
Reconstituted tobacco (recon) is a versatile solution for modern tobacco manufacturing.
It allows you to maximize yield by converting natural leaves, dust, fines, and stems into high-quality cut rag, cigar wrappers, or heated tobacco products (HTP).
Our TDA process offers a distinct advantage over conventional casting methods by using a low-moisture dough. This reduces energy and water consumption by up to 15 times, while preserving the natural taste profile of your blend.
Whether you are producing conventional cigarettes or exploring new HTP formats, our scalable technology provides a low entry barrier and high recipe flexibility.
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