Factory Focus: A Low Oxygen Solution

It pays to modify the atmosphere while controlling insects in stored tobacco.

By Clive Gladman, Griffin Cardwell Limited

A method of terminating all stages of insect life while maintaining the quality of the tobacco is the goal of the solutions that Griffin Cardwell and Oxy-low bring to the tobacco market. The low oxygen solutions include a combination of machinery and packaging equipment for cut rag, DIET and lamina tobacco. The machines create a low oxygen environment inside the packaging by the use of nitrogen. Two different types of packing machines have been developed for different tobacco formats, which bring forward different advantages.

The Oxytemp Packaging Unit is a full automated packaging system designed for lamina tobacco and uses the SMART Out-liner packaging. The Oxytemp places the tobacco boxes in a chamber, and oxygen levels inside the core of the product are rapidly reduced to below one percent by the use of the innovative pressure nitrogen application. There is an option to cool down the tobacco during the cycle. After the treatment cycle in the chamber has been completed, each tobacco box is placed in a SMART Out-liner and heat sealed to maintain the modified atmosphere inside the liner. The unit can be built in at the end of the GLT line or stands alone for product arrival in the warehouse. The machine capacity is designed to fit even the most challenging of customer volumes.

The SFS Packaging Unit is a semi-automatic packaging machine for cut rag and DIET tobacco that comes together with the SMART In-liner packaging equipment. The operation starts by placing a SMART In-liner in the box after which it is filled with product. The box is then moved to the SFS Packaging Unit that creates low oxygen levels below one

percent inside the SMART In-liner by flushing the liner containing the product with nitrogen. The unit closes and seals the packaging maintaining the modified atmosphere inside the SMART In-liner.

The key benefits are secure insect control, quality preservation, cost savings and in a wider sense acting socially and environmentally responsibly.

Each SMART In- and Out-liner is a prefabricated bag to ease the process of placing it in- or outside of the box. The specially designed SMART liners are available in different sizes, among which are the standard C30 and C48 sizes. However, bespoke sizes can be made. The liner is gas tight as it has a multi-layer film structure including an oxygen barrier. All SMART liners can be collected for recycling.

The Benefits There are real and significant savings during storage and transport that can be achieved using Modified Atmosphere Packaging. The key benefits are secure insect control, quality preservation, cost savings and in a wider sense acting socially and environmentally responsibly.

For both the Oxytemp and SFS you obtain effective non-toxic pest management, with a secure, high insect kill rate, usually greater than 99.97 percent. Low oxygen terminates all insects as no insect can become survive low oxygen. (Re) infestation is also prevented given the enclosed environment in which the tobacco is placed.

Further, the quality of the tobacco is maintained as you protect the color and freshness of the product and halter the oxidation processes. This means that the shelf life of the tobacco is extended and the moisture and mass losses that naturally occur over time are minimized. For the Oxytemp one percent to two percent more lamina tobacco mass is retained during 9 to 12 months of storage when compared to conventional storage. A further cost saving is achieved by eliminating the “cool down” area after the GLT process and the tobacco is directly available for further storage or transport.

Besides the benefits for the tobacco itself, the risks for workers and the environment are also minimized, as no toxic fumigants are used. [TI]