The Multi Segment Maker (MSM): a machine for all needs

A technological highlight in this transformation is the Multi Segment Maker. Why the MSM is perfectly suited to the transformation of the tobacco industry is explained by our experts Kai Karstens and Carsten Wulf.

The tobacco industry is undergoing a fundamental transformation, moving its business model into a new era. This shift aligns with the changing habits and behaviors of end consumers. Newly developed Tobacco Heated Products (THP), in which tobacco is heated rather than burned, are considered the innovative alternative to traditional cigarettes.

This fundamental market shift also demands groundbreaking technological innovations. Körber is taking a leading role in this process. A unique response to the changing market demands is the Multi Segment Maker (MSM), which can be configured individually to meet specific customer needs. The MSM is designed for the production of "Heat Sticks“ - tobacco sticks used in tobacco heaters.

What makes it a true flagship in Körber’s product portfolio? Kai Karstens (Executive Vice President Global Sales & Account Management) and Carsten Wulf (Technical Sales Specials) reveal the answer in this interview. They provide insights into the development process, the close collaboration with customers, and the forward-thinking modular machine concept of the MSM.

The tobacco industry is currently reinventing itself. About ten years ago, when the first companies announced their intention to "quit smoking," so to speak, what challenges did you foresee as a technology partner?

Carsten Wulf: Körber had already been developing machines for reduced-risk products in the 1980s. We knew that the global players, with their large research teams, were working on new products that had never existed before. Tobacco Heated Products (THP) were and still are an exciting product segment. These products heat nicotine-containing tobacco sticks instead of burning them, producing lower temperatures and no conventional smoke compared to traditional cigarettes, aligning perfectly with changing market demands. 

Kai Karstens: Even back then, we knew we wanted to play a significant role in shaping this transformation. We saw opportunities to create groundbreaking innovations and bring them to life. This approach is embedded in our DNA: we are the go-to partner for enabling our customers to manufacture their products efficiently and with cutting-edge technology. 

How has the development process between you and your customers changed? 

Kai Karstens: Things move much faster now. The new Tobacco Heated Product technology has significantly shortened the product lifecycle. A new generation enters the market every few years, requiring corresponding machines within the same timeframe. A flexible, adaptive quality product like our Multi Segment Maker (MSM) offers innovation security by being adjustable to meet changing product specifications. 

Carsten Wulf: With the MSM as a foundation, we can quickly implement new product ideas from our customers and bring them to industrial production. That’s why customers involve us early in the development process to minimize the time between product creation and market launch. Unlike in the past, the mindset is changing, and we now continue to develop the machine alongside our customers during production. The materials used in Tobacco Heated Products, especially paper and adhesives, place high demands on machine technology.

What were the first steps in developing the MSM?

Kai Karstens: At the time, our customers didn’t really know where the journey would lead. They only knew they wanted to produce tobacco sticks for a small electronic device where a battery-powered heating element would heat the tobacco. They didn’t have a concrete technical solution in mind but knew one thing: Körber understands the challenges of the industry, listens, and has extensive technological expertise in developing innovative machines.

Carsten Wulf: Specifically, we asked ourselves how all conceivable future customer specifications could be translated into machine technology. From the start, we designed the MSM on a modular basis, focusing on standardized handover points, module sizes, interfaces, and functions. It works like a modular system: each MSM is configured specifically for the customer’s application, combining the capabilities of various successful machine types and further perfecting them through continuous development. We created options to integrate existing equipment, add new modules, or customize individual modules to customer requirements, including retrofits such as quality sensors. Overall, the MSM brings an unprecedented level of flexibility to production. 

Kai Karstens: And that’s not all. Another standout feature of the MSM is its ability to combine multiple process steps within a single machine, such as tobacco stick formation, tipping, laser perforation, inspection, cutting, and turning. This integration reduces the need for personnel, saves space, minimizes logistics components, and increases automation. 

What are customers' primary expectations of you? 

Kai Karstens: Given the shortened product lifecycle of Tobacco Heated Products, speed-to-market is their top priority. Our customers also value the reliability we provide. When we take on a project, they know it will succeed. 

Carsten Wulf: It’s also crucial to approach collaboration in new ways. We collaborate with our customers, developing something entirely new together. This process involves more feedback cycles than before, allowing us to make quick adjustments. Internally, we’ve adopted an agile approach, working in small, interdisciplinary teams to move projects forward efficiently. 

And what other qualities do you need to bring to the table as a technology partner?

Kai Karstens: Above all, entrepreneurial thinking and courage. No one knew if this product would succeed in the market. Together with our customers, we ventured into a new territory, elevating our technological innovations with the MSM to an entirely new level. 

What are the key technical highlights of the MSM? 

Carsten Wulf: It’s easy and user-friendly to operate. The glass doors, behind which the individual modules and assemblies are located, can be fully opened. This provides a significant advantage for process visibility, maintenance, and cleaning. Quick-release mechanisms make it easier for operators to remove or insert components. The platform above the MSM allows safe working at height—a very important consideration in the industry. 

And aside from operability? 

Carsten Wulf: There are several unique technical components, such as the adhesive system, which allows for very flexible handling and control of the type and amount of adhesive applied. Another example is the sensor system, which can create and process 360-degree photos of the products. Are there defects in the tobacco sticks? How perfect is their roundness? Is the product length accurate? These are critical qualities that can be monitored in this way. 

Kai Karstens: What excites me most is the versatility of the Multi Segment Maker. The composition of the stick is constantly changing, and our flexible modular concept is perfect for adapting to all scenarios. 

What role does digital networking play in your customers’ factories? 

Kai Karstens: Of course, the tobacco industry also uses modern technologies like the Internet of Things, artificial intelligence, and big data to optimize production processes. The goal is the Smart Factory – a connected production environment where machines, products, and people communicate with each other in real time. 

Carsten Wulf: With the MSM, we provide exactly the foundation for this. For example, it operates using the OPC UA standard (Open Platform Communications Unified Architecture). This industrial communication standard ensures that machines from different manufacturers can provide data in a unified format. 

Are you already working on the next MSM? 

Kai Karstens: There won’t be a new MSM in the traditional sense. The machine is in a constant state of evolution – it’s continuously developed and optimized to meet customer requirements. 

Carsten Wulf: That’s precisely the security we offer our customers! We can say: you bought the MSM five years ago, and even though your product looks completely different today, you can still produce it with the MSM. We make that possible for you through a simple machine upgrade. The modularity of the MSM provides high investment security. 

Is the MSM team proud of its flagship machine?

Carsten Wulf: We recently conducted a small survey among team members and on-site technicians, and they are indeed proud of the MSM. We are all contributing to its evolution, and our personal stories are intertwined with those of a highly innovative and economically successful technical product. That does make us proud.

And how will the evolution continue? What do you expect for the future?  

Carsten Wulf: We have several things in the pipeline. We want to make the processes even more stable than they are now, further optimize the machine’s energy efficiency, and leverage the opportunities provided by digitalization. Key topics here include automated inspection cycles and automated machine calibration. 

Kai Karstens: This shows that these are exciting times full of change for us and the tobacco industry – and that will remain the case. Körber will continue to be in demand, and I’m looking forward to tackling these complex tasks.