Staff Report
As the tobacco market is increasingly under pressure, facing rigorous regulations worldwide, leading manufacturers are searching for the most efficient, premium quality control equipment. While the removal of foreign matter (FM) or non-tobacco related materials (NTRM) is a specific field of expertise, many techniques and technologies apply. One of them is the ‘optical’ technology.
Market analysis
In 2008, the JT Group decided to execute a detailed market analysis on the latest technologies used in optical FMD-systems. During this process, the JT Group learned that the technology had greatly evolved since their existing laser-based FMD equipments were implemented, making it impossible to further upgrade them with the latest technologies available.
In order to compare the current units with the latest sorting technology, a long-term evaluation test was required. The main focus was to increase NTRM removal/sorting efficiency by decreasing error rejection levels, while looking into the new/enhanced sorting criteria available (such as biological characteristics of tobacco).
Following this, a series of short-term tests was executed. Further required long-term tests in a real production environment were organized at the JTI Trier GmbH facility. These evaluations were performed throughout most of 2009.
BEST laser sorters
BEST Sorting provided its latest laser technology for sorting tobacco. Both its Helius free fall laser sorter and its TB high capacity belt laser sorter (with a Helius hardware processing platform) were put to the stand for long-term evaluation. Each unit was integrated into the primary tobacco expansion-processing line and evaluated in real production conditions by the facility team.
The Japan Tobacco International (JTI) global engineering team also led several off-line tests on PMD-conditioned tobacco-lamina (tobacco blends including Virginia, burley, oriental and/or reconditioned tobaccos) in different percentages. The tobacco industry evaluation test-protocol was used (seeded tests) as JT Group’s specific targets were set forward. Criteria such as ease of maintenance, operability (blend management, blend changes), line integration complexity, user-friendliness and stability of sorting were considered during the evaluation.
Tests with the Helius free fall laser sorter and the TB5 belt laser sorter were successful. Both the sorters complied with the high standards set forward for this evaluation and requested by the JT Group.
Long-term partnership
The foundation for a long-term partnership was set as the JT Group decided, after careful analysis of the parameters set forward during the evaluation, to approve BEST’s (laser-based) FMD-systems. As a result, the JT Group has already committed to purchase multiple BEST sorting machines for various processing plants.
Tatsuya Shimada, JTI Global Engineering FMD-evaluation project leader, said that he became convinced of the quality of BEST’s laser sorters after rigorous testing.
“Both laser sorters satisfied the criteria we set forward, and the product range they cover will ensure that the implementation meets the specifics of our production lines,” Shinada said.
Furthermore, he commented upon BEST’s professionalism: if any observation was made, BEST’s responsiveness and the actions they undertook to overcome them gave JT Group a good feeling about the kind of commitment BEST is ready to make and of the resourceful solutions BEST is able to offer. For example, when asked if a local service team could be available for JTI’s facilities in Japan, BEST committed to setting up a specific operation and hiring competent service engineers to comply with the very specifics towards minimal intervention time. BEST also agreed to make local spare parts available.
Today, this action has nearly been completed and BEST Japan is scheduled to be operational before the first BEST unit is supplied to JT’s Manufacturing Technology Center in Japan.
“BEST is looking forward to this new, challenging partnership,” commented Steven Van Geel, BEST’s area sales manager for the tobacco branch. “We would like to thank the JT Group for this opportunity and the time they have dedicated to the evaluation”.
He further added that BEST is committed to making each of the different sorter integration projects a success.
Close relationship
Furthermore, Van Geel stated that BEST will be pleased to work with the different JT Group affiliates, while a close relationship will also need to be maintained (or built-up if not already present) with the different primary processing equipment integrators with which JT Group has established a relation in terms of equipment-supply.
“Together with the expertise of the JT Group, its integration partner(s) and BEST, we will make sure that any of the (to be) installed sorters will be performing in the most optimal conditions, striving for a consistent NTRM free product,” he said.
As a leading and pioneering designer and manufacturer, BEST will pursue comprehensive market research and continuous development to further strengthen its position on the sorting market. Currently, several new developments are being tested. Once they are ready for commercialization, any of these solutions will have the potential to be implemented within the existing units, without any major additional cost.
