tobacco industry background

TOBACCO INDUSTRY

Tobacco is our lifeblood not only in that it plays a major role in Turkey’s economy and creates millions of jobs here, but also because of the substantial contribution it makes to the finances of OPTIMAL Mechatronics Corporation.

The history of tobacco in Turkey goes back a long way to over 400 years ago when the Ottoman Empire was in reign while its history in our business dates back to 20 years ago, throughout which we have improved our knowhow considerably while also gaining invaluable experience from our large network of local, national and global customers, suppliers, highly-qualified workers as well as from our competitors.

OPTIMAL has a wide range of products, solutions and services for both the primary and secondary. Our areas of specialization in the tobacco industry is generating labour-saving, time and energy-saving resources-recovering, so cost-healing solutions for maker dedusting, pneumatic conveying, mechanical conveying and cut filler feeding.

  1. Design

  2. Automation

  3. Manufacturing

  4. Pre-installation & Testing

  5. Packing & Transport

  6. On-site Installation

  7. Commissioning

  8. Machinery and Work Equipment Relocation

  9. Machinery and Work Equipment Inspection, Maintance and Repair

Wrapping Tobacco Line

 Manufacturing, installation and comissioning of 250 kg/h to 2.000 kg /h wrapping tobacco line.

PRODUCTS

1.Tobacco Handling Products for Primary

A. Tipper

OPTIMAL Mechatronics offers tippers that safely feed whole tobacco leaves and fine-cut tobacco into mini silos right before the feeder from BINs and C48 boxes by means of which tobacco is transferred.

In line with the requirements of Machinery Directive 2006/42/EC, the operator is protected against any risks of occupational accidents throughout the whole process.

B. Tobacco Reclaiming Improvement Machine 

A common problem in tobacco industry is yield loss due to the significant amount of fine-cut tobacco that is trapped inside
defective cigarettes.

Although most Tobacco Reclaim Machine selling companies claim to produce a solution to recover that loss, unfortunately
they cannot meet the pre-committed machine efficiency, thus still causing a considerable loss in output.

OPTIMAL Mechatronics offers a secondary improvement system to recover the fine-cut tobacco lost even after the
primary reclaiming process.

With this Tobacco Reclaiming Improvement machine that we both design and manufacture, OPTIMAL is able to decrease
the loss in yield down to 1%.

C. Conveyors

OPTIMAL Mechatronics manufactures conveyors to serve different purposes. These conveyors are used to convey whole leaf tobacco, fine-cut tobacco and finished products throughout tobacco processing.

C1. Add-back Conveyors

We produce add-back conveyors that feed the smaller tobacco particles that are reclaimed from rejected cigarettes and defective packs of cigarettes into cigarette making machines at pre-determined points once they are recovered.

C2. Belt Conveyors

We make custom-designed belt conveyors to carry whole leaf tobacco and fine-cut tobacco.

C3. Roller Conveyors

We manufacture roller conveyors to transfer the finished products on the pallets, and also to move C48 boxes and BINs easily and safely at the production site.

C4. Vibrating Conveyors

We produce vibrating conveyors to be used for both transferring whole leaf tobacco and fine-cut tobacco, and screening purposes.

C5. Screw Conveyors

We make custom-designed belt conveyors to carry whole leaf tobacco and fine-cut tobacco.

PRODUCTS

2. Tobacco Handling Products for Secondary

A. Dedusting Pipeworks

Flanges and dedusting pipeworks are used in almost every industry. OPTIMAL Mechatronics manufactures and installs those in
a gas-tight welded fashion, using both stainless steel and carbon steel with powder coating in keeping with the world standards.

B. Mobile Jet Pulse Filter Unit

Mobile Jet Pulse Filter, which is very easy to move around, can be operated at any point at a cigarette production site.

It is connected to just one cigarette maker from which both de-dusting and tobacco feeding operations can be performed simultaneously.

C. Glue Tank

Our company constructs glue tanks to convey the glue from IBC tanks, in which the glue is originally brought to a cigarette factory, to cigarette making machines.

D. Maker & Packer Operator’s Desk

So as to enable the operator to run maker and packer machines in an uninterrupted fashion, OPTIMAL makes customized desks on which the operator can keep his hand tools, equipment and apparatus together neatly.

E. Tailor-made Aluminum Staircase

OPTIMAL produces lightweight aluminum staircases of various heights so that the operators and maintenance workers can access the machinery at the production site fast and easily.

F. Transparent Tow Cabinets

While feeding cigarette filter tows into a cigarette filter making machine, the tow feeding machine causes a considerable amount
of dust particles to rise into the air.

To prevent the dust cloud from making the production site dirty, OPTIMAL Mechatronics manufactures transparent, solid, carbon fiber cabinets to cover the tow feeding machine.

G. Glue Removal Room

Our company constructs glue tanks to convey the glue from IBC tanks, in which the glue is originally brought to a cigarette factory, to cigarette making machines.

H. Drainage Systems

In order to drain the dirty wash water used for cleaning purposes at factories without problems, OPTIMAL Mechatronics manufactures self-tilted, modular, subsurface drainage systems and drainage grids made of stainless steel. 

SOLUTIONS

 1. Tobacco Handling Solutions for Primary 

A. Dedusting Systems

OPTIMAL designs, constructs and then installs the complete jet pulse filter system required to transfer tobacco throughout the primary process.

B. Tobacco Casing & Flavouring Solutions

In order to flavor tobacco, raw materials of various aroma and different viscosity are brought to cigarette factories in drums.
So as to add them to the tobacco as instructed on the recipe, cigarette factories need special casing and flavouring preparation kitchens.

OPTIMAL Mechatronics
generates solutions for those kitchens at cigarette manufacturing plants.

C. Central Vacuum Cleaning Systems

Fully-automated and energy-saving CVC systems clean very small dust particles off a production site at a factory using an extremely powerful vacuum system.

This system, which is able to do the cleaning at different spots simultaneously, operates irrespective of the principle of running on a fixed vacuum pressure unit.

The dust particles collected from the floor can be recycled later if it is appropriate to do so. Central Vacuum Cleaning Systems can also be designed in a different way to be used at charcoal filter cigarette production area.

D. Blend Selector

Considering the customer’s special needs, OPTIMAL Mechatronics manufactures blend selectors that enable changing a variety
of blends in the feeding lines that sit on a specially designed platform between feeders and makers easily and in a risk-free way for several different feeder&maker arrangements.

A Blend Selector, which also allows the operator to trace the process comfortably, makes it possible to manufacture with minimum production error.

E. Automated Bin Tipping Systems

Considering the customer’s needs and the physical layout of the facility, OPTIMAL Mechatronics designs and manufactures
fully-automated bin tipping systems with movable tippers and handling systems.

This system has barcode technology, so it is easy to trace production and transfer the bins from one point to another inside the factory safely.

In addition, as the system is fully-automated, fewer workers are needed. This brings two advantages. Firstly, the forklift traffic inside the factory gets lighter, so safer. Secondly, as there are fewer workers at the facility, labour cost would automatically go down.

SOLUTIONS

 2. Tobacco Handling Solutions for Secondary

A. Cut Filler Feeding Systems

We design, manufacture, install and commission tobacco feeding systems for your cigarette makers and feeding machinery of different brands with different capacities.

First, we place the feeding de-dusting system in the spot where the customer wants us to position. We also share our
experience and give recommendations about the ideal spot to locate it at.

Later, we identify the most optimum route for piping so as to get ultimate efficiency. Following that, we prepare a 3D design
of the whole system by making very detailed engineering calculations.

Next, we determine the most optimum diameters for the pipes concerning the velocity of the dust flowing throughout the
pipes, decide on the right dust collection capacity of the filter (kw/hr), thus manufacturing the most energy-saving system
turnkey.

In the piping design of cut filler feeding systems, we highly recommend single airflow control as the velocity in the pipe is
more stable, thus decreasing the loss of quality fine-cut tobacco.

B. Cigarette Maker Dedusting Systems

We design, manufacture, install and commission de-dusting systems for your cigarette maker machinery of different brands
with different capacities.

First, we place the de-dusting system in the spot where the customer wants us to position. We also share our experience
and give recommendations about the ideal spot to locate it at.

Later, we identify the most optimum route for piping so as to get ultimate efficiency.Following that, we prepare a 3D design
of the whole system by making very detailed engineering calculations.

Next, we determine the most optimum diameters for the pipes concerning the velocity of the dust flowing throughout the
pipes, decide on the right dust collection capacity of the filter (kw/hr), thus manufacturing the most energy-saving system
turnkey.

C. Central Vacuum Cleaning Systems

Fully-automated and energy-saving CVC systems clean very small dust particles off a production site at a factory using an extremely powerful vacuum system.

This system, which is able to do the cleaning at different spots simultaneously, operates irrespective of the principle of running on a fixed vacuum pressure unit.

The dust particles collected from the floor can be recycled later if it is appropriate to do so. Central Vacuum Cleaning Systems can also be designed in a different way to be used at charcoal filter cigarette production area.

D. Stem Collection Systems

The stems and non-tobacco related materials rejected by the cigarette maker machine are first sorted out and then collected
by the threshed stem sorting machine. During that process, the stem and fine-cut tobacco are separated from each other.

To do that, OPTIMAL puts a specially designed cyclone between the cigarette maker machine and the jet pulse filter. Thus,
the stems and usable fine-cut tobacco are separated, and the collected stems are reclaimed for cigarette manufacturing.

E. Triacetin & Glue Distribution Systems

OPTIMAL designs and constructs Triacetin Distribution Systems to deliver fluids like triacetin and glue to both cigarette makers
and cigarette filter machinery from a single point.

The advantage of this system is that both the traffic at the production site is reduced and the flow of the fluids can be traced.

F. Charcoal Dedusting Systems

We design and construct charcoal de-dusting systems, in conformance with the ATEX Directive, to collect the dust particles falling off the charcoal filter manufacturing machinery at cigarette filter making plants.

The piping system and casing of the filter are earthed. Spark detectors, explosion vents and fire extinguishers are also integrated
into the system to make it safer in case of an explosion. So, our systems are totally explosion-proof and fire-proof.

G. Machinery Guard & Safety Improvement

OPTIMAL Mechatronics help keep people safe at the production area by complying with Machinery Directive 2006/42/EC.

We assess the risks in using both a new machine to be designed and the existing ones so as to eliminate possible hazards to a minimum and thus protect workers against work-related accidents.

SERVICES

OPTIMAL’s Services for Handling Tobacco Machinery & Equipment 

A. Primary & Secondary Installation and Start-up.

OPTIMAL offers installation service for both cigarette making and cigarette packaging machinery and equipment.

Following a meticulous pre-delivery testing of the machine at OPTIMAL’s facility, the machine is then delivered to the customer’s facility for on-site installation. There, the machine is further supervised by our highly experienced team to ensure smooth functioning of the mechanics, electronic and electrical components and automation of separate parts.

When we confirm that the machine or equipment operates with maximum efficiency, we believe that the delivery has been completed successfully.

B. Primary & Secondary Relocation

OPTIMAL Mechatronics has a specialist team for moving your primary and secondary machinery and equipment both inside your plant and from one plant to another.

OPTIMAL’s professional team has very long years of experience in extracting, loading, moving, unloading and finally relocating
your primary and secondary machinery and equipment. We arrive at your facility with all the equipment required for relocation and we complete this operation with maximum efficiency and in the shortest time possible so that your processes and productivity will not be interrupted.

OPTIMAL Mechatronics guarantees to move your primary and secondary machinery and equipment safely, smoothly and in the most stressfree way to save you time and money.

C. Primary & Secondary Inspection,
     Maintenance and Repair

That machinery and work equipment at factories sometimes pose threats to not only their functionality but also to a safe work environment is a typical problem that modern day fast industrialization and mechanization have brought about.

Such risks may be caused by faulty installation, relocation, careless use, a major modification, getting damaged and sometimes
by just getting worn out over time.

In such cases, upon request, OPTIMAL Mechatronics visits their customers’ factories first to make a comprehensive risk
assessment of the old and in some occasions, newly-installed machinery and work equipment.

OPTIMAL’s expert team carefully examines the machinery and spots the problematic areas. Then, they evaluate the risks to
see if they jeopardize safe working conditions for the operator and other workers or influence the process negatively.

If such is the case, our specialists intervene to take precautions, make the improving adjustments and testing. They keep track
of the problem and how it has been healed. Finally, they decide on the frequency of the following inspections to ensure a safe
and productive working environment at the customer’s plant.

In order not to endanger the working environment and put the flow of the processes at risk, the best way is regular maintenance.

OPTIMAL Mechatronics’s expert team also supplies maintenance and repair services. 

Address

Bahcelievler Mahallesi Orhan Alpyoruk Caddesi No:17/1 Torbali / Izmir / Turkey


Contacts

Email: sales@optimalges.com
Phone: +90 549 500 7913