Eliminate hidden loss with Tobacco Manufacturing System

Connect every machine on your floor, automatically find every stop root cause, and run one standard across every factory.

The complete tobacco factory software for cigarettes and new generation products. Trusted by the world’s largest tobacco companies.

Trusted by leading tobacco manufacturers

Scaled across tobacco production worldwide

Produce Tobacco and Modern Oral Products With Less Stops

Accevo connects high-speed tobacco equipment (running at 10,000 – 30,000 units per minute) to a common data layer, combining PLC signals with operator input to produce reliable, real-time events for OEE and micro stops.

The system provides full visibility of the production, enabling complete transparency so employees can see the actual real-time effects of their actions and actively participate in process improvement.

Micro Stops Intelligence

The MCS algorithm automatically identifies the root cause of every line stop – aligning combined stop with the bottleneck in under 5 seconds.

Loss Tree to Machine Module

Four-level drill-down from line to individual machine module – by domain, SKU, shift, and team. Every level benchmarked against targets you set.

No Machine Upgrades Needed

Our Machine Connectivity layer integrates both legacy and new units via OPC UA TMC. Data flows 1:1 directly from HMI and PLC via HMI-native protocols, ensuring no vendor lock-in.

Brand Change Excellence

Track G2G and B2G changeover accuracy and efficiency from the moment the change starts. See losses by brand change type, measure improvement over time.

IWS-aligned by Default

Built to support the Integrated Work System methodology used by tobacco majors. Loss Tree, CIL, brand change workflows, and standardized data model.

One Standard Across All Factories

Identical data model, dashboards, and workflows across any number of sites. Start with one factory, roll out to the next.

We selected Accevo because of expertise in monitoring and analyzing operational performance. This choice will enable BAT to further standardize and optimize our production processes globally.

Janusz Dziurzynski

Global Head of IT Operations, BAT

The Most Comprehensive Machine Connectivity in Tobacco

Our technology enables direct data collection from machines, and with an in-house automation team, we manage the entire process end-to-end. We use edge devices and signal converters like MOXA to compute and preprocess data right at the machine level.

The operator panel allows to input activities, call for technicians, and monitor the production process. A modern work environment gives operators confidence in the work they do.

SMD (Regular, LCO)

Rod Maker
Strip-cut Maker
Buffer
Packer
Cello
Stamper
Bundler
Case Packer
Outer Coding
Case Labeller

FMD

Filter Makers
AF
KDF
HCF
Unloader
Filter Shooters
Magomat
Taurus

MO machinery

MO products (Snus, Lyft, Skruf, Zone)
Merz / GD MO Maker and Packer
Lid feeder
Can feeder
Checkweigher
Stamper
Can Labeller
Can Outer Packer
Case Packer
Case Labeller

OTP Products

Pouches
Cans
Buckets

OTP Machines

Weighers
Packer
Checkweighers
Pouch coding
Foil wrapper
Bundle Machine
Conveyer systems
Case Packer

Get complete, reliable machine data - regardless of connection quality or machine age

Buffering and resilience against network drops

Where the connection to the server is unstable or intermittent, Accevo’s connectivity layer buffers data for a defined period – preventing gaps in downtime and quantity history critical when micro-stops and short losses matter.

Add what machines cannot tell you

Not everything is available from PLCs. Reasons, activities, and contextual actions require human input. Accevo supplements machine signals with operator input via the panel, closing the loop between what happened and why it happened.

Turn raw signals into usable production events

Raw signals are translated into structured events – run, stop, micro-stop, counts, speeds, and alarms. The outcome is a consistent data foundation that feeds performance monitoring and micro-stop analytics.

Designed to support tobacco operating standards

Accevo’s connectivity layer is built to support IWS-oriented processes – delivering real-time machine awareness supplemented by operator input. Consistent, comparable, near-real-time line data across every site.

Loss tree drill-down to individual machine module

Drill down from line to machine module to find and fix every loss driver – prevent hidden margin loss before it compounds across your operation.

Loss Drill Down / Loss Tree: Deeper than standard OEE. See exactly where losses occur - by domain, machine module, SKU, and shift.
Root Cause Analysis: RCA with 6W2H framework, fishbone analysis, and cause & effect diagrams - fed by live production data, not guesswork.
Brand Change Analysis: G2G and B2G changeover accuracy and efficiency. See which losses follow brand changes and measure improvement over time.

Automatic identification of stop root causes at machine module level

Supported by CenterLine parameter tracking and structured defect handling workflows.

Micro Stops Intelligence (MCS): Automatic recognition of line stop root cause. Algorithm aligns combined stop with bottleneck and reasons from all machine states.
CenterLine Monitoring: Track machine setpoint changes in real time. Ensure the right parameters are set for every SKU - and flag any deviation instantly.
Defect Handling: Report, escalate, and resolve machine defects with structured workflows, photo documentation, and SAP/CMMS integration.

At Imperial, we are transforming the way we manufacture – with data, technology and unified processes. Together, we are building a connected manufacturing ecosystem – simpler, smarter and ready for the future.

Martijn Kuipers

Global Manufacturing Excellence Director, Imperial Brands

Operator panels and supervisor dashboards aligned with IWS daily management

Standardized workflows, confirmed task execution and centralized documentation across all lines and sites.

Operator Panel

Live line state, KPIs vs. target, and CI activity reporting – everything fits into an intuitive interface.

Supervisor Overview

Live multi-line status with color-coded history. Display on shopfloor screens to drive team ownership.

Standardized Processes

One standard way of working across all lines and sites. IWS-aligned workflows, confirmed task execution, centralized documentation.

Full regulatory compliance and track & trace for tobacco

Tobacco operates under strict regulatory requirements alongside a structured Manufacturing Excellence framework. Accevo handles compliance and traceability without adding manual work on the floor.

Tobacco Products Directive (TPD)

Full compliance with EU TPD and equivalent track and trace requirements for tobacco products globally. The system generates and stores all required regulatory data without additional manual steps.

Forward & backward traceability

A complete tobacco traceability system – at pack, bundle, and master case level. Track any unit forward through the supply chain or backward to machine, shift, batch, and operator.

GxP-ready functionality

Digital documentation with operator confirmation, SPC, quality gates, and a full audit trail. Built for environments where every action needs to be recorded and recoverable.

Cybersecurity

NIS2 and CRA aligned. Role-based access control, SSO support, and regular security updates – so your tobacco compliance software stays ahead of evolving requirements.

From One Line to a Global Network

Start with a single production line or workcenter. Scale to dozens of plants with stadardized configurations, unified data, and consistent KPIs.

Running on your machines within weeks. Real data from your own lines – stop reasons, production counters, rejection reasons and centerline targets. Before committing to a full factory rollout.

Real results on your lines in 6-8 weeks. You build on a proven tobacco framework – meaning you get a working system, not a development project.

Standardized playbook for scaling across facilities. Identical data model, dashboards and workflows at every site – so every factory runs on the same standard.

Filtrona: 3 production lines connected in 2 weeks

Filtrona is the only independent global manufacturer of specialty filters for the tobacco industry.

Before a global rollout, we ran a proof of concept on 3 lines. During a single pilot visit, we connected them via dedicated PLC data converters and configured real-time data collection, operator panels and business dashboards. Two lines were modern machines; the third was legacy.

From all 3 lines we collected detailed stop reasons, production counters, rejection reasons and counts, and centerline setup targets – delivered as both operator-facing dashboards and business-level visualizations.

Contact with our Expert

Albert Pawula, Tobacco Industry Expert

A 60-minute online meeting with a dedicated specialist presenting a top system from an industry similar to yours
Live modeling of your production process
A budget quotation after the meeting

Product Catalogue

Stop the stops

Smart Factory Report