A method of processing tobacco fines into a non-continuous tobacco material includes providing a pre-sized tobacco stem material that has a Dp90 particle size of less than 2.5 mm and a Dp50 particle size of between 0.7 mm and 1.5 mm, combining the pre-sized tobacco stem material with tobacco fines to provide a tobacco initial material, wherein the tobacco initial material includes between 40% and 60% pre-sized tobacco stem material (by mass). The method can include processing the initial material by setting the initial material to a predefined increased moisture content, subjecting the initial material to an increase in temperature and subjecting the initial material an increased pressure in order to bind the tobacco fines to the tobacco stem material, and conveying the initial material through a conveyor. The method can include feeding the processed tobacco material through a shearing gap such that the processed tobacco material is defibrated by expansion.

A method of processing tobacco fines into a non-continuous tobacco material includes providing a pre-sized tobacco stem material that has a Dp90 particle size of less than 2.5 mm and a Dp50 particle size of between 0.7 mm and 1.5 mm, combining the pre-sized tobacco stem material with tobacco fines to provide a tobacco initial material, wherein the tobacco initial material includes between 40% and 60% pre-sized tobacco stem material (by mass). The method can include processing the initial material by setting the initial material to a predefined increased moisture content, subjecting the initial material to an increase in temperature and subjecting the initial material an increased pressure in order to bind the tobacco fines to the tobacco stem material, and conveying the initial material through a conveyor. The method can include feeding the processed tobacco material through a shearing gap such that the processed tobacco material is defibrated by expansion.

A leaf removal assembly including a frame comprising a front plate having a feed opening, a leaf stripping assembly mounted on said front plate in front of said feed opening and an upper sprocket wheel comprising a plurality of upper socket grippers extending radially outward of the upper sprocket wheel and being disposed behind the front plate. The leaf removal assembly further includes a lower sprocket wheel comprising a plurality of lower sprocket grippers extending radially outwardly of the lower sprocket wheel and being disposed behind the front plate. At least one of the upper sprocket wheel and the lower sprocket wheel may be adjustably attached to the frame. A process for separating a leaf from a stalk comprising at least one leaf is also included.

A leaf removal assembly including a frame comprising a front plate having a feed opening, a leaf stripping assembly mounted on said front plate in front of said feed opening and an upper sprocket wheel comprising a plurality of upper socket grippers extending radially outward of the upper sprocket wheel and being disposed behind the front plate. The leaf removal assembly further includes a lower sprocket wheel comprising a plurality of lower sprocket grippers extending radially outwardly of the lower sprocket wheel and being disposed behind the front plate. At least one of the upper sprocket wheel and the lower sprocket wheel may be adjustably attached to the frame. A process for separating a leaf from a stalk comprising at least one leaf is also included.

A tobacco cut filler comprises a first tobacco material cut in accordance with a first cut specification, wherein the first cut specification sets at least predetermined first cut width and first cut length.

A tobacco cut filler comprises a first tobacco material cut in accordance with a first cut specification, wherein the first cut specification sets at least predetermined first cut width and first cut length.

A tobacco cut filler comprises a first tobacco material cut in accordance with a first cut specification, wherein the first cut specification sets at least predetermined first cut width and first cut length.

A tobacco cut filler comprises a first tobacco material cut in accordance with a first cut specification, wherein the first cut specification sets at least predetermined first cut width and first cut length.

A stem screening and conditioning device includes a roller, a thermal insulation cover, a spiral feeding device, a compressed-air cleaning device, a steam tube, a discharge hole, and a waste hole. A stem screening and conditioning method for the stem screening and conditioning device is also provided. The present disclosure realizes the complete separation of normal-size and undersized stems under the premise of full moisture absorption, thereby improving the refinement and homogenization level of stem conditioning.

A stem screening and conditioning device includes a roller, a thermal insulation cover, a spiral feeding device, a compressed-air cleaning device, a steam tube, a discharge hole, and a waste hole. A stem screening and conditioning method for the stem screening and conditioning device is also provided. The present disclosure realizes the complete separation of normal-size and undersized stems under the premise of full moisture absorption, thereby improving the refinement and homogenization level of stem conditioning.