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Inventory & Production Management for Tobacco

The control
tower for your
tobacco
manufacturing operation.

Leaf grades, proprietary blends, and excise-controlled production across cigarette, cigar, and next-generation product lines. FalOrb gives tobacco manufacturers real-time visibility into leaf inventories, blend BOMs, production batches, and regulatory compliance records.

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Real-Time StockBlend BOMBatch TrackingMRP PlanningExcise ComplianceAgeing ManagementSupplier ManagementAudit LedgerReal-Time StockBlend BOMBatch TrackingMRP PlanningExcise ComplianceAgeing ManagementSupplier ManagementAudit Ledger
Tobacco Manufacturing operations
01 / The Problem - Tobacco Floor
■ The Problem

Your tobacco plant
runs on
excise-driven complexity.

Leaf tobacco aged for years before production. Proprietary blends requiring specific leaf grades from specific origins. Excise duty calculated per stick and per gram, reconciled against production output. When tax authorities audit your production records, every gram of leaf must account from warehouse receipt through blending to finished product output.

FalOrb was built for the regulatory and inventory complexity of tobacco manufacturing - where excise reconciliation gaps trigger investigations and blend consistency defines brand loyalty.

Pain 01
Leaf Ageing and Inventory Holding
Tobacco leaf aged for one to three years before use. Massive capital tied up in ageing inventory. Leaf quality evolves during ageing. No system tracking ageing status, quality progression, and blend readiness across warehouse locations.
Pain 02
Excise Duty Reconciliation
Production output must reconcile with excise duty payments by stick count and weight. Discrepancies between production records and excise declarations trigger government audits. No automated reconciliation between production batch records and excise reporting.
Pain 03
Blend Consistency Across Batches
Proprietary blends require specific leaf grades from specific origins in exact ratios. Leaf availability varies by harvest year and origin. Maintaining blend taste consistency when substituting leaf grades requires blender expertise with no system support.
Pain 04
Regulatory Track-and-Trace
Increasing regulatory requirements for product serialisation and track-and-trace from factory to retail. Unique identifiers assigned at pack and carton level. No integrated system linking production batch records to serialised finished goods.
Tobacco Manufacturing production

Inventory & Production

Real-Time Stock / Multi-Level BOM / Auto-Costing

Supply chain operations

Supply Chain & Operations

MRP Horizons / Supplier Management / Alert System

Tobacco Manufacturing platform
02 / The Platform - Built for Tobacco Manufacturing
■ The Platform

One system from
leaf warehouse to
excise-cleared product.

FalOrb covers the full tobacco manufacturing lifecycle. Leaf inventory with ageing tracking, blend BOM management, production batch records, excise reconciliation, and track-and-trace serialisation - all connected in one platform.

Every leaf bale is tracked. Every blend batch is recorded. Every excise unit is reconciled. From leaf receipt and ageing through conditioning, blending, and making to packed, stamped, and dispatched product.

■ Platform in Action

See what your
tobacco manufacturing operations
look like inside FalOrb.

Real screens. Real layout. Simulated data from a tobacco manufacturing facility.

01 / Overview

Operations Dashboard

One screen to see every location, every critical item, every in-transit shipment. Health status propagates from stock to location to the organization level.

falorb.com/overview

Overview

Updated just now
Refresh
4
Total Locations
2
Critical Items
3
Pending Transfers
8
Active Alerts
Manufacturing
9
Active Production Orders
1
Material Shortages
0
Products ATP Zero
2
MRP Shortfalls
Network
Leaf Processing & Curing
Production
Low
3 critical 10 low 148 healthy
Tobacco Leaf Warehouse
Warehouse
Healthy
312 healthy 4 surplus
Cigarette Making & Packing
Production
Healthy
5 low 196 healthy
Regional Distribution Center
Distribution
Healthy
428 healthy
02 / Production

Production Orders

Full lifecycle tracking from draft to completion. Material status tells you instantly whether the line can run or needs procurement action.

falorb.com/production-orders

Production Orders

+ New Order
All 9
Draft 2
Confirmed 3
In Progress 6
Completed 3
Order #ProductLocationQty OrderedQty ProducedMaterialStatus
PO-2026-4751Premium Blend Cigarette (KS)Cigarette Making & Packing500,000372,000SufficientIn Progress
PO-2026-4752Reconstituted Tobacco SheetLeaf Processing & Curing18,0000PartialConfirmed
PO-2026-4753Heated Tobacco StickCigarette Making & Packing200,000200,000SufficientCompleted
PO-2026-4754Moist Snuff (Wintergreen)Leaf Processing & Curing35,00016,400CriticalIn Progress
PO-2026-4755Cigar Wrapper Leaf (CT Shade)Leaf Processing & Curing8,0000SufficientDraft
03 / Alerts

13-Type Alert System

Auto-generated, role-routed alerts with one-click acknowledge and resolve. The system detects, you act.

falorb.com/alerts

Alerts

All 8
Active 8
Acknowledged 3
Resolved 1
TypeItemLocationMessageTriggeredStatus
▲Below MinimumVirginia Flue-Cured LeafLeaf Processing & CuringFlue-cured leaf at 7% of minimum; blending operations paused20 min agoActive
▲Humidity AlertBurley Tobacco (Aged 2yr)Tobacco Leaf WarehouseWarehouse humidity dropped to 52%; leaf brittleness risk for aged burley1 hr agoActive
▼Regulatory HoldMenthol Flavoring CompoundCigarette Making & PackingUpdated FDA PMTA documentation required before compound release3 hr agoPending Review
▼Supplier DelayCigarette Filter Rod (Acetate)Cigarette Making & PackingFilter rod delivery delayed 3 days; packing line schedule adjusted5 hr agoMonitoring
●Reorder TriggeredInner Foil Wrap (Aluminum)Cigarette Making & PackingAuto-reorder placed for 15,000 m aluminum foil wrap9 hr agoResolved
Module 01
Location Management
Every plant, warehouse, and zone mapped. Multi-site hierarchy with role-based access control across your entire operation.
Module 02
Item & BOM
Multi-level bill of materials with auto-costing. Component tracking from raw input to final assembly with full version control.
Module 03
Production Orders
Material reservation, real-time progress, and variance tracking across every production run. Full lifecycle visibility from creation to completion.
Module 04
ATP Engine
Available-to-promise. Know what you can make and when, before committing to delivery. Real-time calculation against live stock and reservations.
Module 05
Transfer Engine
Structured inter-location transfers. Request, approve, ship, receive - every step recorded in the ledger with full chain of custody.
Module 06
MRP & Procurement
Demand planning across 7, 14, 30, and 60-day horizons. Purchase order lifecycle and supplier management with automated recommendations.
Module 07
Alert System
13 alert types with auto-resolve capability. Role-routed by severity to ensure the signal reaches the person who can act - immediately.
Module 08
Audit Ledger
Immutable. Every movement, every adjustment, every transaction recorded permanently. Nothing is mutated directly. The single source of truth.
■ How It Works

From stockout
to signal in
under a second.

When a critical material drops below threshold, FalOrb doesn't wait for someone to notice. The system detects, alerts, acts, and records - automatically.

01
Detect
Stock health reclassified in real-time. Four-state system flags the risk level before it becomes a problem.
02
Alert
The right role receives the alert. 13 alert types ensure the signal reaches the person who can act.
03
Act
Transfer request routed. MRP recommendation generated. Production order adjusted. Structured workflow, not ad hoc chat.
04
Record
Every action logged to the immutable audit ledger. Full traceability from detection to resolution.
“
Designed on the factory floor, not in a software lab. Every feature exists because a manufacturer needed it. Not because a product manager imagined it.
- FalOrb, Product Philosophy
8
Core Platform Modules
13
Alert Types / Auto-Resolve
60d
MRP Planning Horizon
4
Stock Health States

Your tobacco plant
deserves excise clarity.

FalOrb is built for tobacco manufacturers where leaf ageing ties up years of capital, excise reconciliation is a regulatory obligation, and blend consistency defines your brand. If that's your operation, let us show you what connected tobacco manufacturing looks like.

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