Hauni’s KD 5RT for Recess Filters
Hauni’s recess renaissance
GERMANY
The global boom in tobacco heated products (THP) has dramatically increased demand for optimized manufacturing processes in the area of recess tubes. Hauni has the answer: the new KDF 5RT.
Three years ago, when Hauni started developing the KDF 5RT, nobody could have predicted such a high level of demand. The initial goal was to design a solution based on the KDF 5, which would ensure a perfectly rounded form and thus highlight the premium nature of recess filter cigarettes. Existing manufacturing processes left considerable room for improvement. Alexandra Wollin, product consultant engineering at Hauni, explains, “For the conventional recess filter production, a double-length gap was left between two acetate segments. To stabilize this product, a very high grammage paper was used as a final wrap. Using a very heavy paper (up to 110 g/mm2) will impact the machine performance, wear, and last but not least the quality of the final product itself. The proper [oval shape] in particular has always been tough to reach. The KDF RT is changing the game: the stiff paper tube created by the RT is inserted in the multifilter maker as an individual segment instead of leaving the gap. We ensured more stable quality, products, and processes by wrapping the multifilter with only a thin plugwrap at the end. The recess segment is manufactured in a separate process.” The anticipated benefits included a reduction in multifilter production costs and a higher quality recess mouthpiece.
Suddenly, in the middle of the development phase, the global boom in THP ignited. The recess filter assumed a new level of importance as a functional segment, and requirements regarding material costs, wear, and tear to machinery and speed-optimized processes increased. “For example, the filters in tobacco heated products contain recess tubes that give the smoke space to cool. After all it is heated to around 350°C,” continues Alexandra Wollin. “Recess tubes made on the KDF 5RT are generally suitable for all THP sticks available on the market.”
KDF 5RT is based on the Hauni platform strategy and combines tried and tested components to create new solutions for manufacturing paper tubes. The key advantage of the new recess manufacturing process is that a double-width paper is cut longitudinally. This is then glued in an offset configuration to achieve the required thickness and strength. When the filter is rounded, the edges fit over each other without an overlapping seam. The visual appearance and roundness are far superior to those of conventional recess mouthpieces.
“KDF 5RT runs at a speed of up to 200 m/min depending on the selected format – anything is possible from super slim to king size,” reports Wollin. “At the same time, we have managed to cut manufacturing costs significantly by reducing both wear and tear and material costs.” As Wollin points out, another advantage lies in the machine’s level of automation. “The only additional components required are paper and cold glue. KDF 5RT is highly automated and provides the perfect foundation for future developments in production technology.”