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Cigarette Flavour Application Systems

Kaymich pioneered the first on-line application system in the tobacco industry for flavour/menthol application. The original system offered the on-line control of flavour application with accuracy to +/- 0.2 mg per cigarette, online monitoring of flavour dosage and automatic eject of 'out of specification' product, virtually no contamination during production and elimination of the need for pre-production planning.

This system became the industry standard with many users buying multiple units to extend the versatility of their production facilities.

AFS1000 Advanced Flavouring Application System

Features

 

• Touch screen controls

• On-line help and advice
• Simple set-up procedures
• Dry joints for quick release
• Load cells measure the tank content
• Handles clear, translucent and coloured liquids
• Twin tanks reduce melt time for menthol crystals (Just 90 minutes)
• Simpler pump design - more reliable
• Increased flow capacity (160ml/minute)
• Split tank design - cleaner, easier refill procedure
• Capable of applying a wide range of flavours
• OEM systems compatible

Benefits

• Easy to move between host machines.
• Easy to use - quick release at all points (tanks and hose)
• Easy set up - touch screen controls with on-line help facility.
• Versatile - handles a wide variety of flavours including dark, opaque and clear liquids.
• Easy to refill - twin tanks reduce melt time (menthol) and eliminates lifting heavy weights during operating/refill.
• Greater reliability - "simpler by design" pump eliminates the requirement for calibration.
• Low maintenance requirements - less sensitive to wear and tear.

System Description

The AFS1000 is designed for the on-line application of liquefied flavour during the Secondary process of cigarette manufacture. The unit can apply heated flavours such as pure menthol, or cold flavour. The AFS1000 can apply a wide variety of flavours regardless of colour or density. 

Flavour can be applied on-line either upon the making machine (cigarette paper or tobacco stream), or upon the filter plug maker. The AFS1000 can also be successfully incorporated configured with the packer for the flavouring of foil.

Accurate to within +/- 0.2mg/cigarette, the AFS1000 employs a low maintenance pump that delivers near pulseless flow.

Suitable for fitment to a wide variety of machines including Cigarette Makers, Filter Plug Makers and Cigarette packers. For specific machine types please refer to Kaymich.

Services Required:

• Dry, filtered non lubricated air 60 - 100 psi/4 - 7 bar
• Electrical voltage 220/240Vac single phase
• CE compliant

Flavour specification:

• Menthol crystals, natural or synthetic
• Viscosity, recommended 4 centipoise at 50°C

For confirmation of flavour capability, please refer to Kaymich

Performance Characteristics:

• Capacity 15kgs
• Temperature range 0°C to 70°C
• Flow rate Maximum 160g/minute equivalent to 16 mg/cigarette at 10,000 cpm
• Minimum 2g/minute, equivalent to 0.5mg/cig at 4,000cpm *
• Accuracy +/- 0.2mg per cigarette
• Dimensions 935mm x 935mm x 532mm

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Paper Applicator

Application onto the paper on the cigarette maker is generally acceptable for dosages up to 6mg per cigarette. Up to this dosage the tobacco is capable of absorbing most flavours (such as menthol)  directly from the paper without resulting in any discolouration.

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Tobacco Applicator

For higher dosages (above 6mg per cigarette) Kaymich recommend that the application is made into the tobacco stream. A unique applicator design ensures that an accurate dosage of flavour is distributed evenly across the stream, allowing the effective absorption of the full flavour dosage, without producing any negative effects upon the quality of the rod produced.

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Filter applicator

The AFS1000 uses the manufacturer's stuffer jet with the flavour applicator mounted on the tow funnel. Flavour is dispensed through a hypodermic needle into the heart of the filter tow. When the machine receives a stop signal, the needle is retracted from the tow and rests in a safe place within the valve body. The exact application position is in the centre of the moving tow, just at the point where the filter paper and the tow are formed within the tongue. Thereby encasing the liquid menthol within the acetate tow and filter paper. 

The UFA on-to Filter reduces the risk of spotting by applying flavour directly into the filter tow. The flavour is completely encapsulated within the tow ensuring that flavour production is completed without contamination of manufacturing equipment downstream from the filter maker.

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Foil Applicator

Application of flavour onto foil has many disadvantages and is not a method generlly recomended by Kaymich.  However, in certain very rare circumstances it may be the most suitable method.  Therefore the AFS1000 can be connected to certain foil rewind systems.  For more information on this please contact Kaymich.

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Remote Heating System  

The RH1A complements the AFS1000 by providing a means of storing, heating or melting menthol crystals that is required in the cigarette, filter or cigar manufacturing process.

The system comes complete with the same design of flask that is used in the AFS1000. The flask is placed into the RH1A where a piston agitator draws in melted flavour from the flask, heats it and ejects it back into the flask. This method aids the heating / melting process as well as providing a limited means of mixing. Thanks to the innovative and patented design of the piston agitator and the advance heating system, the RH1A significantly reduces the melt time of a full tank of solid menthol.

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Tank Agitator 

The cylinder agitator assembly is designed to keep the liquid flavour inside the AFS1000 cylinder moving whilst having the lowest impact upon the AFS1000 itself. The Cylinder Agitator fits onto the standard FS103100 Flavour cylinder, replacing the cylinder lid and requiring only a software change to enable operation. This enables the Cylinder Agitator to be controlled from The purpose of having the ability to agitate the tank contents is to ensure that the consistency and mix of the flavour ingredients remain constant during flavour application. This is particularly essential when a flavour comprises ingredients of different specific gravity. The Cylinder Agitator is fitted with a device to ensure that it can only be started when it is correctly positioned within the cylinder. the HMI to start, stop and vary the speed. 

A variable speed control enables the operator to change the level of agitation within the tank according to the requirements of the flavour. The Cylinder Agitator is not to be used on any material in a solid state. In the event that this occurs, the software will detect that there is no rotation and generate a warning to the operator.