NTRM and Packing: A Revolutionary Approach to Some Old Issues

Source from:  Tobacco Asia  06/19/2013

Sometimes the most effective solution to a problem turns out to be the most obvious – which doesn't always mean that it is the first soltio otbe adopted. GCH Cardwell, in cooperation with BEST Sorting of Belgium and Oxy-Low Systems Europe B.V., re-examined two of the most critical aspects of primary processing – NTRM (non-tobacco related material) and packaging and together they have come up with what are basically obvious, but nonetheless revolutionary, solutions to some age-old problems.

NTRM - The Final solution: Sort It While it's Big

GCH Cardwell, the UK-based division of GCH International. have been working in close co-operation with BEST Sorting of Belgium to develop a new type of sorting system for detecting and removing NTRM from big leaf flows.

BEST, which last year was acquired by Tomra Sorting Systems, announced in 2011 that it had taken a fresh look at GLT sorting and was proposing that big leaf tobacco be inspected at the start of the process, rather than at the end, as was the normal method. The logic behind this move seems impeccable. If the NTRM is allowed to go through the whole GLT process, it, as with the leaf tobacco, is rendered gradually smaller and, therefore, more difficult to find and reject. The solution is clearly to perform the sorting at the beginning of the process. Of course, the threshing process is itself a form of sorting in which the product is classified and heavy pieces of NTRM removed; so, in any case, not all NTRM would remain in the flow of leaf until the end.
BEST provides the intelligence, laser detection, and rejection equipment for its Stratus system, while GCH Cardwell provides the mechanical interfacing equipment, including the important inflow equipment. On the Stratus, an optimal spread of tobacco, with acceptable and non-acceptable leaves and NTRM, is obtained through the combined effect of the different elements of the in-feed arrangement. After entering a customized Mini Swan Classifier, a hovering effect is generated, lifting and accelerating the leaves into a high speed laminar air flow and presenting a mono-layer of big leaf to the scanning area. This equipment has to ensure the leaf flows under the scanning area as a consistent mono-layer because the system runs at a fast rate of approximately 20m per minute, whereas normal sorting systems operate at quarter of this.

The Stratus can handle up to four tons of big leaf tobaccos per hour. But the equipment is modular and customizable, enabling easy integration of multiple units to match the line feed rate and the replacement of the typical GLT handpicking arrangements.

Importantly, though the concept is new, the Stratus is said to comprise modular, highly efficient and cost-effective equipment that uses only proven GLT product-conveying and sorting technologies. As is stated above, the in-feed, for instance, is supplied by a customized Mini Swan Classifier, and the optical sorting platform is based upon industry-proven Helius laser sorting technology.

SMART liner

GCH Cardwell has also teamed up with Oxy-Low Systems Europe B.V. to bring the tobacco industry a revolutionary, cost-effective total packing solution: the SMART liner which was developed and tested in Indonesia over a four-year period at PT Sadhana in Surabaya with the initial concept of securing the tobacco from beetle infestation. During the development and testing the SMART liner highlighted numerous other benefits. It prevents beetle re-infestation, mass loss, mould growth, product discoloration, as well as providing controlled tobacco aging. In addition, it eliminates the use of chemical fumigation and safeguards the entire package in the container/warehouse from water damage.

This unique system can be used for all types of tobacco at all stages of packing within the process, including blended strips, bi products, cut rag, cigars and so on.

There are various options available, again providing a unique packing solution from stacking single/double/triple C48 boxes with different inner or outer liner arrangements.

When using the SMART liner within a GLT, the typical configuration would be three high C48 boxes with the liner being outside, thus reducing NTRM concerns. Once packed, the oxygen level, humidity and temperature within the liner can all be monitored to ensure that there is no leakage. This can be done at the initial stage, at the warehouse, and at any stage before the tobacco is further processed.

Furthermore the total packing system includes custom handling to minimize damage to the three pack during the packing, stacking, primary pre-preparation and transportation.

To provide the ultimate packing solution GCH Cardwell can also offer recovery of the liners.

Clive Gladman is divisional director of GCH Cardwell Ltd. Based in the UK, he travels extensively throughout Asia Enditem