Slicing Plug

[Woodsroad]

Here's a call out to everyone who has ever mulled pressing their own plug.

How do you slice it into flakes?

Yes, you can do it by hand with a sharp knife, and yes, I've seen that exceptionally cool Rube Goldberg-esque homemade cutter

But I'm thinking about using a deli slicer, with a teflon-coated blade. Has anyone tried this? Does it get gummed up?

Thanks,

-Woodroad

 

[DGBAMA]

I seem to remember the slicer idea being discussed and gumming of the blade was the problem. Teflon coated? Not sure, maybe that is the missing link. Share your results if you try it.

 

[Woodsroad]

All of the big commercial machine use a microtome-type cutting action. Perhaps a modified paper cutter would work, but it still leaves the problem of getting a rapid, uniform slice thickness.
The machine in the vid kicks ass!

I can imagine a machine with a pneumatic actuator on the slicer, and a stepping motor running a screw to advance the plug. I just need to find a manufacturing engineer who loves slices!

 

[SmokesAhoy]

That machine is so awesome. Um I think due to the resins anything spinning quick like that will gum up. All the successful designs seem to share some sort of guillotine mechanism in common.

The problem with the deli slicer is they are a bit expensive to try an idea out with. But if you already have one you should give it a go and report back what you find out

 

[Woodsroad]

There's a place nearby that sells and services used slicers. Maybe I could have a go at it there.
Of course, a Cuisinart is another possibility.....

 

[Mad Oshea]

OK Sir, This is what I do, Hand press between the blocks (baccy) and let a sliver out to cut - and slice it with the - Death, Kill , Destroy blade in Your hand- Then slice it in a downward cut at 1/8 to 1/4 inch mark.- Thend group it sideways and cut 1/4 inch chunks. Blend is all that is left. That is the Mad cut-? Watch the cutting equipment for what You need, for how much You need cut. I have equipment going to waist, due to this. A good blade from Don will do the same- And if not-A good thin knife will work. Go simple on anything You do Mad-

 

[Woodsroad]

Mad, I'm trying, but can't understand a thing that you're saying.

 

[vinconco]

Anyone ever hear of a Tech 1 tobacco shredder? They were designed to shred plug tobacco back in the 1800's which is the way most tobacco was sold. You bought it by the inch and they cut the plugs at the store counter for you.

We made a crude press and used c clamps to fashion a plug. Then used the Tech 1 to shred it for use in cigarettes. The Tech 1 makes the perfect cut for cigarettes, a "zig zag" type cut.

 

[Mad Oshea]

You have the plug , ok. Now the shread is -Ok as well. Now go old school! I take the plug and press it betwen two blanks of hard wood- Then after the press. I slice a 1/8 to 1/4 inch with a bucher knife. Old school. In the block as You cut it. So -As You feed it out cut! - A little at a time? Did I not say that? The same as VIn showed without the teck cutter. but old school. Two blocks of wood, a press to do the job, and a sharp blade to cut off the end, Use the end of the block as a cut guide. Can't miss Mad- Help Me Lord?

 

[Woodsroad]

OK, gotcha now, Mad. That will work, but....
I want a faster, more uniform cut from a real plug, pressed under 500 psi.

 

[smokinghole]

Have you looked or antique plug cutters? Many have pretty f-ed blades but you could probably easily replace that with a half decent piece of stainless that you put your own edge on.

 

[deluxestogie]

Good, solid plug can be made at about 3 psi x 24 hours. 30-50 psi is used to make Perique. 500 psi is a lotta 'p's for leaf.

Bob

EDIT: Hand-slicing, with a kulu blade is shown here: http://fairtradetobacco.com/threads/637-Making-Black-Cavendish-Pipe-Tobacco#2

 

[Woodsroad]

Yeah, I'm off by a few hundred PSI....325 is what is needed

Per Jensen of Mac Baren states that their new automated press is 40 tons, 40x40cm
40cm = 15.7”.
15.7x15.7=246 sq"
1 ton = 2000 pounds.
40 ton = 80,000#
80,000 pound ÷ 246 sq" = 325 psi

Multiply 325(psi) times the surface area of your mold (in sq. inches) to get the pressure needed to replicate the Mac Baren automated press.

So, for a 4"x4" mold (16 sq.”) you would need 5,200 PSI or (5,200 ÷ 2000) you would need a press rated at 2.6 tons

 

[vinconco]

I've noticed that when making plug the moisture content is important to have the plug hold it's shape and stick together. It has to dry some to slice well and not gum up the blades.

 

[DGBAMA]

Yeah, I'm off by a few hundred PSI....325 is what is needed

Per Jensen of Mac Baren states that their new automated press is 40 tons, 40x40cm
40cm = 15.7”.
15.7x15.7=246 sq"
1 ton = 2000 pounds.
40 ton = 80,000#
80,000 pound ÷ 246 sq" = 325 psi

Multiply 325(psi) times the surface area of your mold (in sq. inches) to get the pressure needed to replicate the Mac Baren automated press.

So, for a 4"x4" mold (16 sq.”) you would need 5,200 PSI or (5,200 ÷ 2000) you would need a press rated at 2.6 tons

Just because they have a 40 ton press, does not mean that they apply that pressure to press their tobacco. Likely they actually use 50-60% of the rated capacity of the press. Any piece of equipment used at its full potential does not last long and in a production environment equipment is expected to last without breaking down. I would guess their actual pressure applied is substantially less than 325.

 

[Woodsroad]

Mac Baren presses @ 40 tons, or 325 psi at the size of their cake:

 

[Brown Thumb]

Cool Vid. Thanks for sharing

 

[smokinghole]

So it sounds like the press is capable of higher compression but they use 40tons to press.