This chapter embraces the manufacture of cut, cake and roll tobacco, cigars, cigarettes, and snuff. It is impossible to indicate the precise form in which each kind of tobacco-leaf is manufactured for use; indeed, no well-defined line marks the qualifications of each sort, and the great art of the manufacturer is to combine the various growths in a manner to produce an article suited to the tastes of his customers, at a price suited to their pockets. But, in a general way, it may be said that Havana and Manilla are probably exclusively consumed in the form of cigars; Virginia is a favourite for cavendish, negrohead, and black twist, and is largely converted into returns, shag, and snuff; Kentucky, Missouri, and Ohio are used for cavendish, brown twist, bird’s-eye, returns, and shag; Dutch and German make the commonest cigars, k’naster, moist snuffs, and smoking-mixtures; Java and Japan are selected for light cigars, mixtures, and light moist shag; Latakia, Turkey, Paraguay, Brazil, China, and the remainder, are used up in cigarettes, mixtures, imitations, and substitutes.

Damping.—The tobacco-leaves are received by the manufacturer in all kinds of packages, from a hogshead to a seron (raw hide), and of all weights from 1 to 12 cwt. The first process they undergo is “damping,”“damping,” which is necessary to overcome their brittleness, and admit of their manipulation without breaking. For this purpose, the bunches (“hands”) are separated, and the leaves are scattered loosely upon a portion of the floor of the factory, recessed to retain the moisture. A quantity of water, which has been accurately proportioned to the absorbing qualities of the leaf used, and to the weight present, is applied through a fine-rosed watering-pot, and the mass is left usually for about 24 hours, that damped on one morning being ready for working on the following morning. In England, water alone is admissible (by legislative enactment) for damping, except in special cases to be noted subsequently; but abroad, many “sauces” are in vogue, their chief ingredients being salt, sal ammoniac, and sugar.

Stripping and Sorting.—Quantities of leaf-tobacco are shipped in a condition deprived of their stem and midrib, and are then known as “stripts.” Those which are not received in this state, after having been damped, are passed through the hands of workmen, who fold each leaf edge to edge, and rip out the midrib by a deft twirl of the fingers, classifying the two halves of each leaf, and ranging the sorts in separate piles as smooth as possible. The value of the leaf greatly depends upon the dexterity with which the stripping is done, as the slightest tear deteriorates it. Stripts require sorting only. The largest and strongest leaves are selected for cutting and spinning; the best-shaped are reserved for the wrappers of cigars; broken and defective pieces form fillers for cigars; and the ribs are ground to make snuff. For the manufacture of “bird’s-eye” smoking-tobacco, the leaves are used without being previously stripped.

Cutting.—Cutting is the process by which the damped leaves, whether stripped or not, are most extensively prepared for smoking in pipes and cigarettes. The tobacco-cutter which is in general use in this country is shown in Figs. 14 (side elevation), 15 (sectional elevation), 16 (front elevation), and 17 (plan). The main frames a are united by stretcher-bolts b; d is a wooden-surface feeding-roller, on which the tobacco is pressed and cut; c are the upper compressing- and feeding-rollers, mounted in e, carriage-plates extended backwards, forming the sides of the feeding-trough, and hinged to the axle m; f are levers; g, links by which the weight w presses down the upper rollers; h, a crank, and i, a connecting-link for working; j, the cross-head to which the knife k is fixed; l, side-levers or radius-bars for guiding the knife, hinged on the eccentric ends of the axle; m, an axle held in bearings at the back of the machine; on its middle part, which is concentric with its own bearings, are hinged the top roll carriage-plates e, whilst on its projecting ends, which are slightly eccentric, the knife-levers l are hinged; n is a worm-wheel segment; o, a worm; p, a hand-wheel for turning the eccentric spindle m through a part of a revolution in its bearings, for adjusting the contact of the knife with the nose-plate q; r, a worm; s, a worm-wheel; t, a worm-pinion for giving simultaneous movement to all the rollers; u, a spindle, “universal jointed” at both ends, for driving the upper rollers in positions varying with the thickness of the feed; v, a saw-toothed ratchet-wheel, moved intermittently by a catch x, link y, and stud-pin z, v being changeable, and the eccentricity of z variable, for the purpose of regulating the fineness of the cutting. Both ends of the knife move at the same speed, and its surface is made to clear the work by describing a slight curve. The knife is adjusted accurately to the nose-plate, while the machine is in motion, by varying the direction of eccentricity of the axis of the knife-levers to that of the roller-levers. The fineness of the cutting is regulated by varying the eccentricity of a movable stud-pin in a plate on the crank-shaft which gives motion, through a train of speed-reducing gear, to the several rollers. The knives are easily removed and replaced, and require sharpening after every 4–6 hours’ working. Two men attend the machine, one to keep the feed-rollers supplied, the other to watch that the knife is doing its work, and to remove the tobacco as fast as it is cut.

Drying.—The cut tobacco, as removed from the machine, is placed loosely in a layer several inches deep in a large trough, provided with a canvas false bottom; steam is introduced between the true and false bottoms, and finds its way up through the tobacco, which is thus rendered more easily workable. It is next transferred to a similar trough having no false bottom, but a steam-jacketed floor instead; here the tobacco is dry-heated, and at the same time lightened up by hand. Finally, it is taken to a third trough, where cold air is forced through the canvas false bottom, by means of a blower or fan. This last operation dries the tobacco ready for use in the course of some hours; but it has the disadvantage of dispersing part of the aroma, and is therefore generally resorted to only when time presses. In other cases, the drying is conducted on canvas trays. However performed, the drying operation needs the greatest attention, to prevent the moisture being extracted to such a degree as to destroy the profit which its presence confers upon the manufacturer. With drying, the preparation of cut tobacco for smoking in pipes is completed.

Cake or Plug.—The manufacture of “cake” or “plug” is little carried on in this country, as the Excise laws exclude the use of sweetening matters, except when carried on in bond. The process is sufficiently simple. Virginian leaf, with or without the addition of flavourings, is sweated for a day or two, to deepen the colour, worked into a soft mass, and next placed in moulds, and subjected to sufficient pressure to ensure the cohesion of the mass. Each cake is then separately wrapped in perfect leaf, and passes through a series of moulds, each smaller than the last, and under increasing pressure in steam-jacketed cupboard-presses, of which there are many forms. The combined effect of the heat and pressure is to thoroughly impregnate the whole mass with the natural juices of the leaf and the flavouring (if any has been used), and to produce a rich dark colour.

A machine for turning out plug-tobacco in ribbons, made by the McGowan Pump Co., New York, is shown in Fig. 18. The tobacco is first weighed out in the proper quantities, and spread in a box placed in spaces in a heavy iron table a. When the latter is filled, it is passed to and fro under the heavy iron wheels b, which are loose on the shaft, and which can be adjusted to exert any desired pressure. Twice passing through suffices. The ribbon is made in lengths of 10 feet, and either 5¾ inches or 2? inches wide, as desired.

Roll or Twist.—Roll- or twist-tobacco is made by spinning the leaf into a rope, and then subjecting it to hot pressure. Until recently, the spinning was performed by hand, much after the manner of ordinary rope-making by hand. But this slow process is now superseded by a machine made by Robinson and Andrew, of Stockport; it is spoken of in very favourable terms by English manufacturers, and received a diploma of merit at the Philadelphia Exhibition. The machine consists of a combination of 3 rollers, whose surfaces are made of segments, to which lateral to-and-fro motions are given by cams attached to the stands on which the axles of the rollers rotate. The tobacco occupies the central space between the 3 rollers, and it is carried through the machine by the lateral to-and-fro motions given to the segments. The fillers and wrappers are laid on a table joined to the machine. The filler is placed in the cover, and they pass together between the rollers, whose action twists and compresses the tobacco into a roll; this is carried forward and wound on a bobbin, revolving in an open frame, and provided with a guide for equalizing the distribution of the tobacco.

The machine is shown in Figs. 19 (elevation), 20 (plan), and 21 (end view). The tobacco is laid on the table a, provided with a rib n, on which the sliding rest b is free to move to and fro; c d are the two lower segmental rollers, the axles of which revolve in stationary bearings; e is the top roller, the axle of which revolves in sliding bearings, fitting in the swing-frame f, and each acted upon by a spring o, pressing on a pin communicating with the bearing, and putting an elastic pressure on the tobacco.

Each segment-roller consists of an axle with four segments, best shown in Figs. 22 and 23. The outer shell of the segments is made of hard wood, fitting an inner shell of malleable cast-iron, the projections on which suit grooves on the cast-iron axle. The segments of the rollers c d are moved laterally to and fro by the wedge-shaped cams p q r s, fixed to the bearings of the roller-axles; and the segments of the roller e are moved in the same manner by cams t u, fixed to the swing-frame f. The tobacco occupies the central space between the 3 rollers, and the cams p r t move the segments in the direction of the arrow where they touch the tobacco, while the cams q s u move them back. After the tobacco has passed beyond the segment-rollers, it goes through the hollow trunnion of the open frame g, in which the bobbin h revolves; the other trunnion of the frame g is provided with fast and loose pulleys, by which the whole machine is driven. To this trunnion, are also fixed an ordinary friction-break pulley, and a grooved pulley, around which latter passes a band for driving the pulley on the axle of the bobbin h. To the other end of the axle of the bobbin, is fixed a pinion, which, by means of a toothed chain, gives motion to another pinion fixed to the double screw i; this double screw gives a traversing to-and-fro motion to the guide j, for distributing the tobacco evenly on the bobbin, by means of a swivel T-headed stud, connected with the guide, and taking into the thread of the double screw. The guide is provided with two horizontal grooved rollers, between which the tobacco passes, and with two other rollers to guide the tobacco on to the bobbin.

Rotary motion is communicated to the segment-rollers c d e as follows:—To the hollow trunnion of the open frame g, is affixed a pinion, which drives the wheel k, on the same shaft as the change-pinion that drives the wheel gearing into the pinions on the axles of the rollers c and d, and one of which pinions gears into the intermediate pinion l, which drives the pinions on the axle of the roller e. The driving-strap is held upon the fast pulley by a drop-catch acting on a weighted lever, one arm of which is connected by a link to the lower end of a strap fork-lever. When it is requisite to stop the machine, the attendant kicks the point of a catch off the end of the lever, which is then raised by the weight, and so moves the driving-strap from the fast to the loose pulley, the stoppage being virtually instantaneous. The mode of working is as follows:—The spinner and assistants stand at opposite sides of the table; the fillers and wrappers being placed on the table, one assistant spreads out the wrapper and pushes the end towards the filler, which the spinner supplies and holds against the sliding-rest b; the rotary motion of the segment-rollers c d e twists the tobacco, and causes the wrapper to be wound over the filler, and the rest b, being movable, enables the spinner to regulate its position according to the quantity and quality of the filler and wrapper. The lateral motion of the segment-rollers passes the roll towards the bobbin, on which it is wound, as described. The combined rotary and traversing motions of the rollers consolidate the tobacco, and put the desired face upon the twist. The roller e is supported in a swing-frame, which is lifted off the tobacco when starting the machine. When the machine is at work, the swing-frame is held down by the stud m (Fig. 19). The figures represent a machine suitable for manufacturing Limerick roll; for pigtail and other small descriptions, it is necessary to reduce the diameter of one or more of the segment-rollers.

A more recent improvement in this machine, by J. E. A. Andrew, is shown in Figs. 24 (side view), 25 (transverse section), and 26 (plan). The table a, rib n, and sliding-rest b, and two lower segment-rollers c d, are constructed as usual; but the axles of the segment-rollers revolve in bearings g h, bolted to the flanges of swivel-frames i k, hinged upon the fulcrum-shaft x; the object of thus supporting the bottom rollers c d is to be able to vary the distance between them according to the thickness of the twist of tobacco that is being rolled. When the distance between the rollers is fixed, the bearings are secured by bolts passing through segmental slots. The solid top roller e revolves in centres in sliding bearings fitting in the swing-frame f.

As the bobbin is filled, it is removed, and replaced by an empty one. The rope is then unwound, and formed into rolls, by the aid of a spindle with flanges at the sides, worked by a treadle, under a cushioned weight which squeezes the coils closely together as they are wound. The completed rolls are subjected to great pressure in steam-jacketed presses, in the same way, and with the same object, as the cakes or plugs.

Cigars.—Cigars are composed of two parts, a core formed of pieces of leaf placed longitudinally, known as “fillers,” and a covering formed of perfect leaf, called the “wrapper.” Probably all the best cigars are made by hand, the only tools required being a short-bladed sharp knife, a receptacle containing an emulsion of gum, and a square wooden disc or “cutting-board.” A portion of perfect leaf is first shaped to form the wrapper of the cigar; then a bunch of fillers is moulded in the hand, and rolled up tightly in the wrapper, the taper end being secured by gumming. Expert workmen make the cigars remarkably uniform in weight and shape. When made, they are sorted according to colour, deftly trimmed at the thick end, and placed in their boxes in cupboards heated by gas-stoves to finally dry or season before being stored for sale.

In America, machinery is introduced wherever possible. Moulds for shaping the cigars are made of hard wood, sometimes partially lined with tin, and of every possible size and form. A machine is made by Dubrul and Co., of Cincinnati, for working 3 sets of moulds at once, 2 being kept filled up under pressure while the 3rd is being filled, or the bunches are being rolled up. A handy little machine for rolling the fillers for cigars is that known as Henneman’s, made by Dubrul and Co. The demand for scrap-made cigars, or those manufactured with short fillers, has caused the introduction of machines for cutting and sifting scrap. One made by Dubrul and Co. is shown in Fig. 27. It consists essentially of a cylinder formed of hook-shaped, double-edged steel blades, revolving against 3 series of fixed but adjustable steel blades, thus permitting the size to be regulated at will.

Cigarettes.—Cigarettes consist of paper tubes filled with cut tobacco, with or without an external wrapper of leaf tobacco. Preference is usually given to those made by hand, but machines have been introduced with some success for making the commoner kinds. A French machine for making cigarettes is shown in Fig. 28. Its work consists in making the paper tubes, and filling them with tobacco. The paper, previously prepared, in a band about 3 inches wide, is unrolled from the coil a by means of the carriage b, and cut off in pieces about 1 inch long for presentation to the mandrel c, temporarily introduced into one of the tubes of the mould-carrier d. The mandrel has a clamp which grasps the paper and rolls it, and, at the moment when the latter escapes from the carriage, its free end is brought upon a rubber pad covered with gum, hidden in the illustration. The paper tube is left in the mould, the mandrel being extracted by means of the cam e; the mould-carrier is then turned ?₉ revolution by the cam f, a new tube comes into line, and the operation is repeated. When 6 paper tubes are completed, the first one is pushed by a small piston, actuated by the cam g, upon the end of the filling-tube; and immediately the rod h, actuated by the cam e, drives into this tube a portion of tobacco already prepared in the compressor i. In preparing the tobacco, a workman, occupying the seat m, is necessary to dispose the material in regular layers on a carrier, by which it is transported into the compressor. When the cigarette-envelope is filled, the mould-carrier again makes part of a revolution, and the finished cigarette is pushed out of the mould by the rod k, also actuated by the cam e; a device finally lodges the cigarettes in the box l. One workman is said to be able to turn out 9600 cigarettes in 10 hours by the aid of the machine.

Snuff.—Snuff is entitled to the last place in the series of tobacco manufactures, as it is largely made up of the scraps, cuttings, and rejections of the preceding processes. The materials are chopped very fine, placed in heaps in warm damp cellars, “doctored” with various flavourings, left to ferment for several weeks, and then ground to powder in edge-runner mills, some kinds even undergoing a slight roasting. When ground, the mass is passed through “mulls,” wood-lined, bottomless bowls, let into a bench, where the snuff is softened and rendered less powdery by means of pointed pins, resembling domestic rolling-pins, which slowly travel around the sides of the bowls. Snuff represents a highly profitable article manufactured from materials that are otherwise useless, and depending for its flavourflavour chiefly upon the perfumes and flavourings used. Hence these last are kept profoundly secret by the manufacturer.

From refuse tobacco which is unfit for any other purpose, is made a decoction for washing sheep and destroying vermin; often the waste is ground very fine, and used by gardeners, presumably to keep noxious insects away.

Miscellaneous Appliances.—The customary ingenuity of the Americans has invented a profusion of admirable labour-saving machines for almost all the operations of the tobacco manufacturer. A few of these only can be noticed in the present article.

Fig. 29 shows a portable resweating-apparatus, intended for darkening the colour of tobacco to suit the dealer’s market. It measures 4 feet long, 3 feet wide, and 5 feet high, being just large enough for one case (400 lb.) of tobacco, including the case; it consists of a water-tank a, a pipe b for conducting the water into the metallic pan c, at the bottom of the apparatus, which is heated by gas-jets d. The tobacco is introduced by the door e, which is fitted with a thermometer. The roof is sloped so as to determine the flow of the water of condensation. The steaming occupies 3–5 days, and needs occasional watching. The apparatus is made by C. S. Philips and Co., 188 Pearl Street, New York.

Fig. 30 illustrates a complicated machine, introduced by C. C. Clawson and Co., of Raleigh, N. Carolina, for putting up large quantities of tobacco in parcels of 2 oz. upwards. It consists of a central table provided with automatic scales for weighing out the portion; four equidistant guides which determine the form of the package; a plunger for packing, and a follower for raising the package; a side-table carrying tongs for holding the empty bags; and another to receive the packages, and hold them during tying. The hopper being supplied with tobacco, and the machine put in motion, each form takes a bag from the tong-table, and the article having been weighed, is carried to the form by a shute, when it drops into the bag, is packed by the plunger, and transferred to the tying-table. With 2 girls or boys, it is said to weigh, pack, and tie 30 bags a minute.

The New York Tobacco Machine Co. make two forms of machines for granulating tobacco, chiefly for making “Killickinick” and cigarettes, their working capacity ranging from 200 to 2000 lb. a day. The cutting-rollers are covered with cross-millings at right angles to each other, those running lengthwise being deep; the fixed cutters are adjustable, so that the cutting may be either coarse or fine. When working, the action is like that of a pair of shears, except that the cross-millings reduce the strips to a granular state. Both stems and leaves may be worked up. The great advantage claimed for these machines is that, though the tobacco should be dry, the percentage of dust escaping is reduced to a nominal figure.

A cutting-machine made by the same Co. is shown in Fig. 31. It is adapted to cut leaf, stem, scrap, plug, or any form of tobacco, to any required degree of fineness, turning out 300–400 lb. a day. The action is almost precisely that of a chaff-cutter. The Co.’s sifting-machine consists of an adjustable cylindrical wire sieve, with a rattan-broom screw-roller revolving inside. The stems are stripped and worked out at one end, while the remainder is broken up, and passed through the sieve, falling upon a perforated tray, through which pass the finest particles for snuff-making. A machine largely used in America is the stem-roller, for crushing and flattening the stems so that they may be used like leaves for making cigars. Great benefit is anticipated in the United States from the adaptation of Ryerson’s “attrition mill” to snuff-grinding, owing to the fact that the pulverization is accomplished without the particles being heated in the least degree. Of cigarette-making machines, there are many kinds; the best are those which deal with the tobacco in a comparatively dry state, thus preventing shrinkage after packing.

Indebtedness is acknowledged to Hy. Archer and Co., Borough, S.E., and T. Brankston and Co., Carter Lane, Doctors’ Commons, for opportunities of inspecting their thoroughly representative works, and for much information readily given concerning the manufacture in this country; to W. Jollyman, of W. D. and H. O. Wills’ London house, for having revised these sheets before going to press; and to Hy. A. Forrest, 61 Broadway, agent of the New York Tobacco Machine Co., for valuable material relating to American machines and processes.