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For pipe smokers, there is more to it than mere enjoyment. Pipe-smoking is a culture in itself – an expression of lifestyle.
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Partial-pallet warehouse
The raw tobaccos are stored here ready for weighing. A blend (mixture) can consist of up to 30 different raw tobaccos, so that the blending process is carried out strictly in accordance with the recipes which have been developed by the Blend Manager. One employee weighs the raw tobaccos with the help of the balance on the right-hand side of the picture and fills the mixing ingredients into the tobacco cart until further processing in the vacuum chamber.
Vacuum chamber
The tobacco leaves which have been put together to form a mixture are then moistened and warmed in a vacuum chamber with steam. As a result of the simultaneous drawing of a vacuum, the steam can be absorbed better because the pores of the leaves open. Furthermore, the leaf becomes supple and its brittleness decreases, which is an advantage for further processing.
Feeder
The structure of the tobacco becomes looser and initial mixing of the ingredients is carried out.
Belt weigher
On the belt weigher, the weight of the tobacco is determined and then the amount of the sauce which is sprayed on the tobacco in the drum casing ascertained by means of a computerised control system.
Steam tunnel
In the steam tunnel the tobacco is moistened and warmed through nozzles with steam so that the casing in the saucing drum is absorbed better and the formation of grit is reduced.
Casing drum
The casing required for this is mixed in the sauce kitchen in accordance with the recipe from natural and nature-identical aromas. In the saucing drum the tobacco is sprayed with the casing. As a result of its rotation, the drum ensures the even application of the sauce and the intensive mixing of the sauced tobacco. During the production of Pueblo (100% tobacco without additives), only water is added to the tobacco.
Mixing boxes
The sauced tobacco is conveyed to the mixing boxes, where it is distributed evenly in horizontal layers. The mixtures remain for a significant time in the boxes, where the applied casing can be absorbed and moisture equalisation takes place. Due to the vertical removal, mixing of the sauced leaf tobaccos is guaranteed.
Cutting machine
The cutting machine is loaded from the mixing boxes. In it, the tobacco is conveyed from two chains located one above the other in a wedge shape to the cutting drum. Six blades attached to the drum cut the tobacco to the desired cutting width, depending on the drum speed and the chain feed motion.
Roasting (dryer)
By means of a feeder, the cut tobacco is fed to the roasting process. The cut tobacco is roasted and dried to the desired final moisture in a drum dryer at temperatures of up to 180°C. The water added during the treatment of the tobacco is removed and as a result of the roasting process, the sauce ingredients combine with the tobacco.
Cooling belt
Cooling is subsequently carried out on a cooling belt with a plentiful supply of fresh air. The finished tobaccos are then weighed on a weighing station, filled into boxes and transported to the cut tobacco store.
Cut tobacco store
The finished tobacco is put into immediate storage here and continuously checked with respect to its quality. Monitoring of the tobacco’s moisture plays a very important role here in particular, as the tobacco must not become too moist or too dry.
Flavouring
Here is where many fine-cut tobaccos get their top flavour. These again are natural or nature-identical flavourings, e.g. fruit and spice extracts, which are mostly based on alcohol (brandy, rum, whiskey). In the flavouring drum the top flavour is dispersed over the tobacco by means of a nozzle, giving each tobacco mixture its unmistakable character.
The packaging of smoking tobaccos
In the smoking tobacco packaging process, the tobacco is packed on fully automatic machines. On several packing machines, cardboard tins with different filling quantities are mainly produced. Furthermore, there are wrapping bag packers with different filling quantity requirements. In the rectangular tin packer, only pipe tobacco is vacuum-packed in tin cans. With the vacuum we achieve a long shelf-life. The finished packs are checked by a checkweigher. If the nominal filling quantity does not correspond to the specifications of the packaging regulations, the goods are rejected. After the check of the weight, the pack is provided by machine with a tax strip. Then the finished packs are combined in foil, paper or retail cartons to form trading units. These units are then packed in corrugated cardboard boxes or plastic boxes, stacked on pallets and sent to the finished goods warehouse.
Many things in life require practice. The use of a tobacco pipe is no exception here. Whoever wants to smoke a pipe, needs time to learn in order to enjoy it in peace. The Basics of Pipe-Smoking will accompany you on your way to perfect enjoyment.
To start, stuff the tobacco loosely at the bottom and a bit more firmly at the top of your pipe. If possible, do not light your pipe with a conventional lighter. Use matches or a special pipe lighter. Here, make the tobacco surface glow evenly with a horizontal flame.
Peace and quiet
You need peace and quiet for smoking. Draw gently on your pipe, always paying attention to ensure that the light does not go out.
The right way to draw on your pipe
Make sure your pipe is not too hot. After all, you do not want to burn your hands on the bowl. Apart from that, you can only really enjoy the tobacco in a cool pipe. If it does get too hot, put the pipe aside and wait until it has cooled down.
Stuffing the pipe again
From time to time, use your tamper by gently pressing it on the tobacco surface. By doing this, you ensure sufficient drawing resistance and an even burning of the tobacco.
Tips
If the light goes out before you have finished smoking the tobacco, do not relight, but instead empty the pipe. This protects your pipe and above all your taste buds.
You should only smoke a pipe once per day. It takes a certain time until the pipe is properly dry again after use. Owning multiple pipes would therefore be advantageous. After each smoking experience, take your special pipe cleaner and clean your pipe carefully with it. A clogged tobacco channel prevents true pipe enjoyment.If you follow this advice, smoking your pipe will be an unforgettable experience – day in, day out.