Facilities

Tobacco Services

USFC’s 500,000 square foot facility contains a climate-controlled storage, a CRES line, a primary, and a secondary with five cigarette make/pack lines.

Primary

Our cut rag process has the current capacity to process 14,000 tons annually, which can be increased based on customer demand. Customer-specific blends utilize the world’s best flue-cured tobacco grown by our members in the USA. American blends also include premium burley and oriental tobaccos. Our customers receive specialized blends designed to satisfy cost and sensory requirements.

Depending on needs of the customer we have the ability to:

Create high quality English or American blends
Match blends from customer provided samples
Apply casing and humectants
Match required moisture, nicotine and tar levels
Match cuts per inch

Secondary (Make/Pack)

Our make/pack operations currently include five production lines, each capable of producing 8,000 cigarettes per minute – one line produces 100mm cigarettes and the other four lines are for 84mm cigarettes. We use industry-leading making and packing equipment: Protos 80 ER maker, GD X2 packer, Montrade case packer, Senzani case packer, and some of the latest technological advancements including laser perforation capability and inked code dating.

We also have KDF and Pipe/RYO equipment – 2 KDF R2s that produce 4,000 filter rods per minute and Kaymich Gemini menthol application system. We also have an ITM Polaris filter maker with the capability of producing single and dual capsule filters. We produce pipe and RYO tobacco in 6 oz. and 16 oz. bags.

Cigarette production quality control procedures include:

State-of-the-art filter rod and cigarette test stations equipped with Statistical Process Control (SPC)
Match blends from customer provided samples
Apply casing and humectants
Match required moisture, nicotine and tar levels
Match cuts per inch