LEADERS IN MANUFACTURING TECHNOLOGY - Al-Mansour …
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LEADERS IN MANUFACTURING TECHNOLOGY
Transcript of LEADERS IN MANUFACTURING TECHNOLOGY - Al-Mansour …
LEADERS IN MANUFACTURING TECHNOLOGY
History
FreeZone
Factory (full)
Factory (brief)
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Contents
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History
The seeds of our success
No major business can separate its own history from that of its
nation - Mansour Group is naturally committed to the economic
development of Egypt, and like Egypt, possesses a proud heritage
of renewal and growth.
Our success story began in 1975 when the late Mr. Loutfy
Mansour successfully gained the national distribution rights for
General Motors. The rapidly expanding company is now affiliated with many of the world’s global giants, including Caterpillar,
Compaq, IBM, McDonalds, Michelin, PMI, and UPS. In addition,
the Mansour Group maintains an investment portfolio that
covers tourism, agri-business, entertainment, and both industrial
and real estate development.
The Mansour Group’s annual turnover approaches two billion
US Dollars and employs a work force of more than 11,000
people, making it one of the largest private sector companies in
the region.
It’s all about location..
In 2000 Mansour Manufacturing Company received government approval in order to
manufacture tobacco products in the Alexandria Free Zone. This allowed the company to
exercise its activity under article 37 (Year 2000). The factory was built on an area of 13 thousand
square meters in the Amreya Free Zone area in Alexandria, Egypt.
Free Zone
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Operations
Different elements working together..The factory is one of the most advanced in its field of manufacturing tobacco cigarettes, it is equipped with central air conditioners that control each section independently, allowing
us to maintain required temperatures and humidity levels according to international
manufacturing specifications. Dust treatment machines work by separating the dust particles by air filtration and distillation units.
The factory also has a waste disposal company that collects all garbage and waste - and
Mansour Manufacturing has acquired the most technologically advanced manufacturing
processes in our effort to reduce our environmental impact.
Mission
Core Production..
The factory manufactures tobacco cigarettes to satisfy the local and international needs,
producing either our own brands or other brands upon request. This increases investments
made in the free zone and creates more opportunities for employment and boosts national
income through our free zone transactions.
Our factory makes two of our own brands; Virginia blend (Forum) and American blend
(Potomac), besides those manufactured for other brands.
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5 FREE ZONE
Quality and speed in a high-paced world
• Two complete production lines. Each line produces 5,000 cigarettes per minute
• Three units for purification and mixing tobacco for manufacturing. • Each unit can supply four production lines with enough tobacco.
• One filter production line that produces 4,000 filters a minute• One unit that treats defective products and enters them in the production line again.
• One unit treatment for tobacco dust
The factory is equipped to expand its production capacity to produce 60,000 cigarettes per
minute.
The factory also has a lab facility that ensures quality control for our products according to
international specifications.
Manufacturing capacity
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Factory
Bringing it all together..
1) Filter Production:
FILTER MACHINE (CANDOR, CALLISTO & ARIES)
Filter production rate is 4000 filter sticks per minute and each filter stick is enough to produce 6 cigarettes, this amounts to enough filters per minute to produce 24000 cigarettes. The filter is produced using the latest technologies with natural raw materials; cellulose, which is treated, wrapped, and shaped according to the required specifications for the cigarette. The quality of the filter is continuously checked during the production process to ensure that the filter’s quality meets international standards.
2) Storage Silos:
(SILO , BAND CONVYOR & BOX TIPPER)
Storage silos for tobacco mixing, filtering and feeding to production lines. The factory contains 3 storage silos, each one can supply 4 production lines and keep the humidity ratio and temperature for 24 hours. The tobacco retains its required qualities and flavour.
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3) Production:
Cigarette Production & Packaging:
• Cigarettes are produced using the latest technologies, receiving the tobacco after it has been filtered from impurities (dust and sticks) in machines electronically controlled to maintain required cigarette specifications (weight, diameter, glue and filter). The best kinds of natural glue are used for the manufacturing process ands sub-par materials are automatically rejected.
Manual quality assurance throughout the production process leaves nothing to chance.
• Our Two production lines produce 10000 cigarettes a minute.
• Identical cigarettes are then delivered to the HLP 250 packaging machine to be packed in their specified packs. The cigarettes are tested for quality, after which they are wrapped and packed. The packs are then delivered to a cellophane wrapping machine. Every 10 packs are wrapped
together in a carton and the cartons are delivered to the cellophane wrapping machine, then
they are manually boxed. Each box takes up to 50 cartons.
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Cigarette manufacturing machine MARK9
Cigarette to filter attaching machine MAX SPackaging cigarettes into plastic packs machine MASS FLOW TRAY M.F.T
Packaging and cellophane wrapping machine HLP
Loading packs into cartons machine SERIUS
Wrapping cartons with cellophane machine MARDEN EDWARDS
4) Extraction:
During this stage, cigarettes that don’t match the required specifications (DELPHI) are put in a cylinder and re-usable tobacco is separated from the filter and paper.
5) Filtering & Dust Collection:
Here, tobacco is filtered from dust and fed to production machines.
DALA MATIC CASED DUST FILTERS
There are 2 air vacuum units through which air is sucked and used in transporting tobacco
from tobacco silos to the production machine, as well as collecting the dust in special bags
which are treated with a natural perfume in order to prevent air pollution.
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Extra Facilities & Features:
1) Quality assurance lab through which the tobacco quality is checked before production. Raw
material specifications are checked before production, as well as the filter production process to ensure that it meets production standards. The production and wrapping processes are also
checked.
2) Store for spare parts that are needed for operation or maintenance.
3) Workshop for periodical and preventive maintenance.
4) Electricity production unit. There are 3 Caterpillar generators with a power of 750 kVA each. These generators are sufficient for current operation and future expansions.
5) Unit for the production of pressurized, dry, dehumidified and oil-free air. There are 3 Atlas Copco AFF compressors.
All of our employees receive training courses in fire fighting.
The whole factory also contains central air-conditioning for each production hall and storage
area in order to maintain the appropriate temperatures and humidity levels in each area inde-
pendently and protect the tobacco, raw materials, and finished products.
CertificateCigarette making
Standard specification
POTOMAC Full Flavor American Blend
Description Target Unit
Cigarette Length 84 mmCigarette Diameter 79 mm
Rod Length 63 mm
Filter Length 21 mm
Die Print Logo POTOMAC
Filter Estron-Acetate Tow (Natural Celluose)
Nicotine 1 mg
Tar 13 mg
FORUM Full Flavor Virginia Blend
Description Target Unit
Cigarette Length 84 mmCigarette Diameter 79 mm
Rod Length 63 mm
Filter Length 21 mm
Die Print Logo FORUM
Filter Estron-Acetate Tow (Natural Celluose)
Nicotine 1 mg
Tar 15 mg10
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Factory Manufactures: Tobacco Cigarettes
We manufacture two of our own brands:
Virginia blend (Forum) and American blend (Potomac).
Other brands are manufactured upon request.
Reasons for choosing Alexandria, Tobacco Free Zone
Most advanced machinery / storage techniques
Vast experience in field of tobacco manufacturing
Strategic Location: Low transportation cost
Located next to the Alexandria port
Close proximity to the Suez Canal
Crossroads between Africa, Asia and Europe
Free Zone: No Taxes
Low labour costs
All non tobacco materials are acquired locally and from best quality.
Factory in Brief
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Alexandria Headquarters:
Address: Canal El-Mahmoudia St.
Hagar El Nawatia ,
Alexandria, Egypt
Telephone: (002) 03 505 1600
Fax: (002) 03 505 1610
Factory Headquarters:
Al Amreya Free Zone Alexandria, Egypt
Telephone: (002) 03 450 0135 – 03 450 0126Fax: (002) 03 450 0155
mmd.mansourgroup.com
