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Bag sealer boosts loose-leaf tobacco sales

A compact, flexible bag-sealing system enables Farmer’s Tobacco of Kentucky to enter the roll-your-own market. Solution minimizes costs and labor for startup product.

band sealer. Pictured is the interior of the B-500 continuous hand sealer with its heating and cooling bars and Teflon bands.
band sealer. Pictured is the interior of the B-500 continuous hand sealer with its heating and cooling bars and Teflon bands.

In recent years, the tobacco industry has faced many challenges resulting from increased competition from cheap foreign imports and intense litigation. Confronted with falling prices and shrinking revenues, many family farms have gone out of business. Yet, fourth-and fifth-generation Kentucky tobacco growers Bob Ammerman and his son Mike have found success with a model that emphasizes whole leaf tobacco and exacting quality standards for their cigarette products.

The Ammerman’s company, Farmer’s Tobacco of Cynthiana, Inc., Cynthiana, KY, launched the Kentucky’s Best brand of cigarettes in 2001. The cigarettes are made with top-quality whole leaf tobacco that does not require added chemicals to enhance burn rate or retain flavor. These features have helped Kentucky’s Best become one of the quickest-growing brands in the industry.

Recently, the Ammermans saw an opportunity to expand their established brand with a product line extension. Because of higher tax rates on carton cigarettes in Kentucky and many neighboring states, there has been increasing demand for “roll your own” (RYO) tobacco delivered in a bag format. This represented a significant opportunity to expand the Kentucky’s Best brand into the RYO market.

Having previously concentrated exclusively on premade cigarettes in cartons, Farmer’s Tobacco required an entirely new packaging solution to offer their tobacco as a RYO option. A key requirement was a resealable bag that would keep the tobacco fresh during storage and use. An additional need was a flexible solution that would allow for different bag sizes and future packaging line upgrades.

A packaging challenge

The key challenge was to design a packaging line concept that would convey, weigh, and package loose-leaf tobacco. At the Farmer’s Tobacco facility in Cynthiana, tobacco is processed from a centralized delivery system. Boxes of tobacco blend are loaded into a main hopper that distributes incoming product to different machine stations throughout the factory.

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