Shisha tobacco has been used by various cultures for thousands of years. The smoking process used today is different but the shisha tobacco remains fundamentally the same.
Equally, while an array of manufacturing and packaging machines are making the manufacturing process easier, the process is effectively the same as it has always been. As a manufacturer you should understand the shisha tobacco manufacturing process.
What You Need to Start Manufacturing Shisha Tobacco
Financial Assistance
Manufacturing shisha tobacco costs money. You need a business plan and at least 12 months worth of finance.
Certification
Make sure your product and business is fully certified before you start trading.
Space
Space is essential to cure, mix, blend, and pack your shisha tobacco. Only you can decide the exact amount needed.
A Grower
Freshly harvested leaves are essential for shisha tobacco production. A local grower will work best.
Target Audience
Knowing your customer makes it easier to sell to them.
Processing And Packaging Machines
Finally, as part of the manufacturing process you’ll need several machines.
Process Of The Shisha Tobacco Manufacturing
There are six main elements of the shisha tobacco manufacturing process. Your business needs to move through each stage if you want to create high-quality shisha tobacco. It’s the quality which will help you build a loyal customer base.
Growing Plants
Manufacturers of shisha tobacco either need to grow plants or source high-quality leaves. Shisha tobacco is created by using the leaves from a traditional tobacco plant and adding flavors. It’s also possible to make a nicotine-free version from the leaves of fruit plants.
There are many different types of tobacco plant, you’ll need to decide which ones will help you create your preferred shisha flavor.
Curing
Curing is another word for drying. It’s an essential part of the shisha tobacco manufacturing process. There are several different ways to dry shisha tobacco. These include air drying, sunlight, and by using a fire.
The aim is simple, to remove all moisture from the leaves. It can take several weeks to achieve this depending on the method you’ve chosen.
To dry leaves effectively inside you’ll need to use dehumidifiers. These will absorb the moisture from the atmosphere and prevent it from going back into the leaves.
Adding Flavour
Once your leaves are cured you’ll want to wash them and remove any stems, it’s just the leaves you’re after. You can then crush them and add the appropriate flavor.
The exact ingredients will vary depending on what flavor you’re after. Honey is generally added in a ratio of three to one. That means three grams of leaves to every gram of honey. It’s normal to add glycerin and a selection of flavorings.
If you’re just starting out then you’ll need to adopt a trial and error approach to find the right flavor for your shisha tobacco.
Combining And Ageing
You can do this by hand or by machine. The larger the batch the easier it is to mix all the ingredients together in a machine. Mixing can be completed by hand but its possible that the flavor will not be evenly distributed.
Once the ingredients are mixed, you’ll want to leave the mixture to ferment. In this regard, it’s just like red wine. Leave it to age and the flavor improves. You just need to decide how long to age it for.
Packaging
Your shisha tobacco is effectively ready. However, before you can think about packaging and sending it to your suppliers, you need to undertake a quick quality check. That means verifying the current moisture content and sampling the product to ensure its flavor is right.
Only when you’re happy with this can you put your shisha tobacco into your tobacco pouches and add the appropriate labels. You should note there are rules governing the size of your tobacco pouches and what information must be declared on them.
Distribution
All that’s left to do is to send your shisha tobacco to your suppliers. You’ll need a reliable delivery service. The best one for your business will depend on several variables, such as how many packages you’re distributing and how far they need to go.
FAQs
Here are the most frequently asked questions. If the answer you seek isn’t here then ask us, we’re happy to help.
Is It Worth Starting A Shisha Tobacco Manufacturing Plant?
Starting a shisha tobacco manufacturing plant can be a costly process. It can also be a very worthwhile endeavor. The secret is to know what you’re getting yourself into before you start,and to create a plan that ensures you have the finance you need.
Are There Packaging/Compliance Issues?
Yes, shisha tobacco must be sold in certain weights and the package sizes are controlled. In addition, the government demands certain information is printed on all shisha tobacco labels.
Getting your shisha tobacco product labeling right is essential if you want to stay within the confines of the law.
Is The Ageing Process An Important Part Of Manufacturing?
Absolutely. Ageing adds flavor and improves the quality of your shisha tobacco. The question is, how long do you want to age it for to get the best results?
Which Flavour Shisha Tobacco Should I Manufacture?
Only you can answer this! There are hundreds of shisha tobacco flavors in existence. You can choose to replicate an existing one or try to create a new one. The best way to decide is to look at what your target consumer enjoys and make one that appeals to them.
