The heart of production
Breathtaking speeds are commonplace in the “Secondary”. This is the home of cigarette and filter makers. Cigarette makers combine the essential components of a cigarette, namely the tobacco and cigarette paper. Filters and strips for the mouthpiece are added for filter cigarettes. For every step, Hauni offers technical solutions that are characterized by outstanding process engineering and quality. For our machines, 95% efficiency is no problem.
On-site at any time
At Philip Morris International in Berlin, the AREO module IAS has been in operation for several months – opening a new dimension in support based on real-time data analysis and digital assistance whenever production problems arise.
The global trend toward tobacco heated products (THP) has dramatically increased the need for an optimized production process for recess tubes. Hauni’s answer: the new KDF 5RT.
With the KDF 2NEO, Hauni has launched a future-proof successor to the world's best-selling filter maker – the KDF 2/ 2ER – onto the market.
Always enough on the roll
Without paper, no cigarette. Four to six kilometre long strips of paper are wound onto large paper rolls, the so-called bobbins. That sounds like a lot but it's enough for only 15 minutes of production time. After which, the rolls are changed automatically. Hauni systems ensure that paper is supplied continuously, safely, and reliably.
Pneumatic filter feed
Filter, filter, filter
Speed and reliability are also key with filters. Hauni's filter stations can be equipped with up to ten modules simultaneously – and every module shoots up to 2,500 filters per minute using compressed air. The pneumatic, practically wear-free machines set standards in other regards as well. For example, they clean themselves automatically: filters in the area around the filter feed drum are removed automatically and the machine restarts itself after a fault.
20,000 cigarettes per minute makes 1.2 million per hour makes more than 8 million cigarettes per shift – the Secondary must be capable of dealing with these extraordinary quantities. Hauni's conveying systems ensure a perfect connection from one production step to the next. All the while, handling the products very gently. Moreover, the machinery is extremely reliable, flexible, and can easily deal with cigarettes and filters of different sizes.
We keep things flowing
Freshly produced cigarettes or filters cannot always immediately be processed further. If, for instance, there are fluctuations in production, there may be an “excess supply” of filters. Or cigarettes. Or both. This is where our reservoirs come into play: they can buffer up to 200,000 filters and temporarily store cigarettes for up to 14 minutes. They enable us to regulate the product flow and ensure greater effectiveness.
Loading and unloading required
What happens to the finished products that shoot from the machine in huge quantities? They can be buffered and cached in open trays. The trays are loaded and unloaded at breathtaking speed. Hauni has machines that can change the trays four times a minute – there is space for 4,000 cigarettes in one tray. Despite this speed, the cigarettes are handled gently and the processes are flexible and reliable.
High-bay tray storage
The big solution
For cigarettes and filters that are finished but have not yet been packed, and are to be stored temporarily in trays, Hauni has developed a fully automated high-bay store. At any given moment, the system and operator know exactly how many cigarettes and filters of which brand are currently in the store. The store creates a buffer that is entirely decoupled from filter and cigarette production. All of this increases productivity and flexibility.
Software solutions for production optimization
Monitor, analyze, optimize
How did the system perform during the last shift? How high is the quality of the cigarettes? These are questions that are of enormous interest to manufacturers. AREO provides comprehensive production and performance data in real-time and helps to make the factory more efficient by analysing data and reports. Without investments in new machines but individually coordinated with the requirements on site. Is it secure? Absolutely, it meets the highest security standards.
Years of innovation