Why cigarette tubes tear during filling and how to prevent it
Does the machine split the tube at the end, tear it along the side or fill it only halfway? Each of these symptoms has its own likely cause. Below are the causes in the order it makes sense to check them: from the most common and least expensive to the one that requires a spare part.
1. Too much tobacco in the chamber
This is the most common cause. If there is more tobacco in the chamber than the tube can hold, the injector pushes it with too much force and the tube splits open at the end. Place tobacco loosely into the chamber without packing it down, and do not pile it above the chamber rim. How much tobacco goes into one cigarette is explained in How much tobacco goes into one cigarette.
2. Tobacco that is too moist
Moist tobacco sticks together in a lump. The injector pushes it as one piece and the tube cannot withstand the pressure. Check the tobacco before filling: a pinched clump should slowly open back up. If it stays stuck together, leave it open for a few hours. More details are available in our tobacco storage article.
3. Tobacco that is too dry
The opposite extreme: dry tobacco crumbles, and small pieces get trapped between the injector and the tube and cut it. Rehydrate such tobacco in a closed container with a piece of apple or a humidifying stone, and avoid filling directly from an open pouch that has been sitting for several days.
4. Dirty chamber or injector
Tobacco residue on the injector increases its effective diameter and therefore friction. Clean the chamber and injector with the supplied brush after each use. The process is described in our cleaning guide.
5. Wrong size or poor-quality tube
A king size tube on a machine set for 100 mm, or vice versa, will not fill correctly. Crushed tubes from an opened box and lower-quality tubes also tear more often. Which size belongs with which machine is explained in King size or 100 mm.
6. Tube not pushed on fully
If the tube is not pushed fully onto the holder, the injector may push it away instead of filling it, or tear it at the beginning. Push the tube on as far as it will go before pulling the lever.
7. Worn injector or tube holder
If you have checked everything above and the tubes still tear, it may be time for a spare part. A bent or worn injector tears tubes along the side, while a worn tube holder does not grip the tube properly and allows it to slip. Both parts are inexpensive and can be replaced at home in a few minutes. Which part matches which symptom is explained in Which spare part do you need?.
Quick overview
| Symptom | Most likely cause |
|---|---|
| tube splits open at the end | too much tobacco |
| tube tears along the side | worn or dirty injector, dry tobacco |
| tube tears at the beginning | not pushed on fully, worn tube holder |
| tube is only half filled | too little tobacco, overly moist tobacco |
| tube slips off the holder | worn tube holder, wrong size |
