How to reduce waste in snus production – and increase profitability
Table of Contents
How much snus and cans are actually lost?
It's a question we've asked ourselves more than once after seeing plastic bins filled with discarded cans – often for small deviations like a crooked label or a jar that weighs half a gram too much.
In an industry where every millimeter, gram and second counts, small losses can quickly become big costs. Snus powder spilled during refilling, portion bags sorted out on the line, batches discarded at the slightest suspicion of deviation. All of this is everyday life in snus production – but that doesn't mean it has to be taken for granted.
At the same time, it is easy to understand why the demands are so high. Consistency, hygiene and quality are non-negotiable. But somewhere a gap arises – between the precision of the technology and the realities of production – where both resources and money risk going up in smoke.
So what does it actually look like?
What can be influenced?
And where do you start if you want to reduce waste – without compromising on quality?
What is waste in snus production?
Waste in snus production is a more widespread problem than one might think at first glance. It is not just about a few discarded prills or a little snus powder spilling – but about systematic losses that affect both economics, sustainability and efficiency. In an industry where precision and quality are crucial, even small deviations quickly become costly on a large scale.
Here are some of the most common types of waste that snus manufacturers deal with every day:
- Raw material waste – for example, tobacco leaves that are not used or spilled during mixing/refilling.
- Packaging waste – boxes, lids, labels, shrink film and portion bags that do not meet requirements or the design has not been optimized.
- Discards of finished goods – vials or cans that do not meet quality standards and must be discarded, sometimes entire batches due to contamination or expiration date.
Why does it occur?
- Production variations in raw materials and process technology.
- Lack of early detection of errors – which causes errors to continue down the line.
- Design and material choices that are not fully adapted for optimal operation and recycling.
- High cost of destruction and handling when finished units must be discarded.
Initiatives and technical solutions to reduce waste
Here are some of the key technologies and process improvements used in snus and portion production:
Automated monitoring & quality control
Camera and sensor-based systems that detect errors (e.g. incorrect weight, incorrect label placement) in real time and take immediate action. This reduces the risk of errors progressing and leading to greater scrapping.
Read more about our Machine Vision solutions.
Digitalization, IoT and AI
Production equipment that is connected and collects data continuously. AI analytics reveal patterns, signal maintenance, and adjust settings autonomously – leading to fewer disruptions, accurate batch management, and less overproduction.
Track & Trace – traceability at the next level
As regulatory requirements increase, traceability has become a central part of snus production. With our Track & Trace solution, each can receives a unique ID that follows it through the entire chain – from labelling to pallet. This enables complete traceability, meets current legal requirements in the tobacco industry and minimizes the risk of errors and manipulation. The system documents every step, providing both security and control in production.
More efficient use of energy and resources
In modern snus factories, energy consumption is optimized according to needs and production rate, which reduces resource use and lowers operating costs. Many facilities also recover excess heat or use closed systems to reuse process water.
A clear example is BAT's Fiedler & Lundgren factory in Malmö, which has achieved carbon-neutral operation and been certified according to the international water standard AWS – proof of how technology and sustainability goals can go hand in hand in the snus industry. Read more
Smarter packaging and materials
Packaging design plays a bigger role than you might think. By using recyclable or biodegradable materials, as well as optimizing the size and shape of the cans, the snus industry is reducing its packaging waste. An example is Swedish Match, which has introduced cardboard boxes made from recycled fiber and plastic boxes with lower chemical content – solutions that both reduce environmental impact and make production more resource-efficient.
Reuse of products and by-products
With the right technology, even what was previously considered waste can become a resource. One example is our can divider – a solution that automatically opens return or disposal boxes, empties the capsules, separates the lid and base, and sorts the materials for reuse or energy recovery. This means that both snus and packaging materials can be reused instead of being thrown away.
Larger players are also actively working on recycling. At one major snus producer, for example, discarded prills and snus flour are collected and mixed with biofuel for combustion, while plastic parts are ground separately to enable recycling. In this way, factories can reduce the need for expensive special handling and at the same time reduce their waste – both environmentally and economically.
Our innovative dose divider
Economic benefits and cost savings
Waste is not only managed for environmental reasons – there is a clear business benefit:
- Reduced raw material costs – every gram of powder or every dose or piece of material saved is a direct profit.
- More efficient operation & increased productivity – fewer stops, higher utilization rate, more approved units per time.
- Lower cost of waste management – reduced need for destruction, better recycling rate, less external handling.
A calculation showing the effect
We recently calculated an example of what it actually costs to discard cans and snuff pellets that do not meet quality requirements – cans and snuff that in many cases could have been saved. It is not just about material waste, but also about unnecessary production costs, time loss and destruction costs. The greater the production, the greater the impact.
Number of cans produced/day: 100,000 pcs
Approx. percent incorrect doses/day: 0,5%
Number of incorrect doses/day: 500 pcs
Number of working days/year: 360 days
Cost per faulty can: NOK 2,5
Calculation:
Max number of cans/year: 36,000,000 pcs
Max number of incorrect boxes: 180,000 pcs
Cost/day for incorrect doses: 1,250 SEK
Cost/year of faulty boxes: 1,250 SEK
The results show that even relatively small percentage improvements result in significant savings – and contribute to both better finances and the environment.
Download our calculation.
Our latest innovation – the dose divider
As demands for both sustainability and efficiency increase, the need for smart solutions becomes increasingly clear. That's why we want to highlight a concrete step forward in the fight against waste: our own developed can divider.
It is designed to automate a part of the production chain that is often handled manually or not at all – namely the handling of return and scrap cans. The can divider opens each can, empties the prills, separates the can parts and sorts the materials so that they can be returned to production or go to energy recovery.
This is not just a technical aid – it is a practical tool for taking control of both waste and resources. For those who want to reduce unnecessary costs, optimize resource use and make a concrete contribution to sustainability, the dose divider can be a smart investment to integrate into daily operations.
The dose divider is just part of our range – see the full range of machines adapted for the snus industry.
Do you have any questions or concerns? Contact Joachim Rohdin, Machinery Division Manager
joachim.rohdin@logimark.se
010-444 16 21
