How do they make smokes?

The process of making cigarettes involves several intricate steps, from the cultivation and processing of tobacco to the final manufacturing and packaging of the cigarettes. Here’s a detailed overview:

Tobacco Cultivation and Harvesting

The process begins with the cultivation and harvesting of tobacco. There are primarily two types of domestic tobacco: bright (or Virginia) and burley. These types have different characteristics and are blended to achieve the unique taste of American cigarettes135.

Processing Tobacco Leaf

After harvesting, the tobacco is dried through a process known as curing. The cured tobacco is then shipped to facilities where the stems and veins are separated from the lamina (the preferred part of the tobacco leaf). The lamina is aged for up to two years to mellow and develop its flavor. During this time, the crop is evaluated for its characteristics to determine the best blending formulation13.

Preparation of Tobacco Components

Several components are prepared for the tobacco blend:

• Reconstituted Leaf (RL): Made from stems, small lamina, and other particles of tobacco. These are processed into a sheet form, treated with hot water to separate water-soluble materials, and then mixed with flavorings, preservatives, and humectants before being dried and cut into laminar-sized pieces1.
• Blended Leaf (BL): Comprised of burley stems and small tobacco particles, ground to a uniform size, blended, and mixed with processing aids. Pectin is released to bind the particles together, and flavorings, humectants, and preservatives are added before forming a sheet1.
• Improved Stem (IS), Expanded Stem (ES), and Expanded Tobacco (ET): These are made from tobacco components that have been expanded or puffed up. IS and ES use bright tobacco stems, while ET uses cut bright and burley lamina with added sugar and humectants. These expanded products reduce the amount of tobacco needed and lower tar and nicotine levels14.

Blending and Conditioning

The various tobacco components, including bright, burley, and oriental tobaccos, are blended according to specific formulations for each cigarette brand. The blend is conditioned with steam to increase moisture and reduce breakage. Flavorings, humectants, and other additives are applied to the different types of tobacco before blending134.

Cigarette Manufacturing

• Creating the Cigarette Rod: A spool of cigarette paper is unrolled, and a line of tobacco is placed on it. The paper is wrapped around the tobacco to form a continuous rod23.
• Cutting and Filtering: The rod is cut into shorter pieces, and filters are inserted at both ends. The filters are connected with tipping paper, and each shorter rod is cut in half to produce two filtered cigarettes23.

Final Processing and Packaging

• Flavor Application: Final flavorings are added to the tobacco using denatured ethyl alcohol. This alcohol must be used because the flavorings do not dissolve in water1.
• Packaging: The cigarettes are packaged, sealed, and prepared for shipment. Quality checks are performed at multiple stages to ensure consistency and quality23.

This comprehensive process ensures that each cigarette meets the specific brand's formulation and quality standards.