Tobacco Services

Facilities

Partnerships

USFC’s 500,000 square foot processing and manufacturing facility contains a climate-controlled green leaf storage, green leaf threshing line (GLT), a CRES line, a primary, and a secondary with five cigarette make/pack lines.

Green Leaf Storage

This 180,000 square foot area can hold up to 10 million green pounds of tobacco in steel racks stacked 5 high in a climate-controlled environment.

Green Leaf Threshing (GLT)

Our GLT can process up to 12.5 tons of tobacco per hour with an annual capacity of 50 million pounds during the flue-cured tobacco season. Staged thresher lines are available in various widths – 96” wide, 72” wide and 60” wide.

Throughout the process, we monitor moisture content with infrared meters. We can hand-pick on 6 lines and use Hauni TS8 optical sorters to remove NTRM (non-tobacco related material).

At the end of the flue-cured season we also have the ability to process burley tobacco in our facility.

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 – three lines produce 100mm cigarettes and the other two 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 produce pipe and RYO tobacco in several sizes – 1 oz., 6 oz., 7 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

Our GLT can process up to 12.5 tons of tobacco per hour with an annual capacity of 50 million pounds during the flue-cured tobacco season.