Tobacco cultivation, cigar production - cigar know-how from DonCigarro

No one knows exactly when tobacco was first cultivated, but there is hardly a doubt where this occurred. The indigenous Americans were not only the first people to farm this plant, but also to smoke it. The Taino and Siboney Indian tribes native to Cuba named the tobacco plant "Cohiba".

Until 1492, the year Christopher Columbus discovered the land we now call America, tobacco was unknown to the rest of the world. With his return to Europe, the plant was introduced to Portugal and Spain. The custom of smoking spread, however, very slowly out of Spain by way of the aristocracy and the royal houses. In 1717, cigars made from Cuban tobacco were called “Sevillas”, after the name of the city in which they were manufactured. Soon after, a better quality was demanded and thus Sevillas were replaced by Cuban cigars. By the middle of the 19th Century, there were already 9,500 tobacco plantations on Cuba, and factories shot up like mushrooms from the earth. America was the most important export market.

The Unique Mix of Sun, Seed, Earth, Love and Expertise

Other countries such as Honduras, Dominican Republic, Nicaragua, Jamaica, the USA, Italy and Holland, including Switzerland, produced very good cigars as well. Each region created it’s very own characteristic taste in a cigar. However, it is the special geographic location, the quality of the earth, the climate, passion and expertise, which make the Havana cigar unique from generation to generation, and this over centuries.

Over many years when the Cubans speak of cigars, they no longer mention Puros or Havanas, but rather HABANOS.

Habanos is a registered trademark and is the generic term for all Havana labels. The name is geographically protected, as is, for example, Cognac, Champagne or Scotch Whisky.

The Areas of Tobacco Cultivation

Over the course of centuries, five zones of tobacco cultivation have formed on the island of Cuba:

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Oriente Province
Las Villas
Camaguey
Region Remedios
Partidos (South of Havana)
Vuelta Abajo (Pinar del Rio Province)

They are divided in to seven districts: El Llano, Lomas, Renate, Guane, Mantana, Costa Sur and Costa Norte.

The finest plantations, the “Vegas Finas” are located in the district El Llano, between the municipalities of San Luis and San Juan y Martinez. However, the best plantation of all is that of Don Alejandro Robaina in San Luis; in 1997, an own cigar label was created in his honor, the Vegas Robaina.

Through the special combination of alluvial land and sandy earth which is found no where else in the world, this soil has become unsurpassed as that in which to cultivate tobacco, and thus guaranteeing exceptional harvests.

Interesting Facts about the Tobacco Plant

Although the tobacco plant is not edible, it is cultivated on a large scale. It’s scientific designation, Nicotiana, is named after the French researcher Jean Nicot. Tobacco belongs to the family of night shade plants (Solanacea), which include the potato, tomato, paprika and chick pea. By the way, they all contain nicotine, if only in minute concentrations, however. The tobacco plant has a characteristic pyramid form, whereby the largest leaves are found at the base of the plant, becoming continually smaller as they are found higher on the stem. The color of the blossoms vary between white and pink.

The Climate

The tobacco plant is very dependent on environmental conditions such as temperature, sun exposure, and humidity, and grows best between 20°C and 27°C. Frost and temperatures below 14°C slow down it’s growth, although the plant can survive temperatures down to –3°C over short periods. In temperatures above 40°C, the delicate leaves burn.

Three Cultivation Methods

Tapado para capas naturales: The tobacco is grown under white tulle cloth coverings, which are stretched on stilts over the fields immediately after planting. It’s purpose is to prevent excessive exposure to sunlight, to keep harmful insects at bay, and to protect the seedlings from the wind. In this way, the precious wrapper leaves retain their smooth, silky and distinctive texture.

Tabaco del sol ensarto: The tobacco is fully exposed to the sun in order to encourage a greater variety of flavors to develop.

Tabaco rubio: This designation indicates an artificially-dried “blond” tobacco, which is used in the production of cigars.

Habanos contain Two Types of Tobacco

The Corojo-Plant for the delicate Wrapper:
Named after the famous El Corojo Vega Plantation where it’s seeds were developed, this sort only supplies leaves for the wrappers (Capa), and whose cultivation is more costly than the production of any other kind of tobacco found in a Habanos. The Corojo leaves found on the stem are divided into seven different harvest categories. To make things even more complicated, the wrappers are additionally sorted according to color: Claro (light brown), Colorado Claro (medium brown), Colorado (dark brown), and Maduro (black). The topmost leaves are normally too oily to be used for wrappers and are instead used in the filler.

- Flower
- Full-bodied, strong leaves
- Full-bodied, slightly less strong leaves
- Finest wrapper quality
- Finest wrapper quality
- Mild wrapper quality
- Very mild wrapper quality or for filler

The Criollo-Plant for the Filler or the Binder:
The Criollo-plant produces four of the five tobacco leaves which are blended into the filler in order to create the diversity of taste variations which one can find in the numerous, different Habanos labels. The Criollo rounds out the completed blend to make it a symphony of flavor. It is the original tobacco of Cuba.

- Flower
- Full-bodied, strong leaves (filler tobacco)
- Full-bodied, slightly less strong leaves (filler tobacco)
- Aromatic, moderately strong leaves (binder or filler)
- Aromatic, moderately strong leaves (binder or filler)
- Aromatic, mild (binder)
- Aromatic, mild (binder)

The Cultivation of Tobacco

The National Tobacco Research Center provides seeds to the tobacco farmers (Vegueros). Only the very best and most resistant seeds are employed. So that the tobacco can prosper optimally, it needs as loose a soil as possible. The fields must be plowed several times before the seedlings can be planted in October. These seedlings are between 15 and 20 cm tall at this point – 45 days after sowing. After a further 45 to 50 days, the tobacco plants reach their full ripeness. During this time, each plant is regularly controlled, weeded, insects destroyed, and any side growth removed. When the tobacco plant has reached it’s full height, the flowers are removed in order that all energy be directed into leaf development. Within three months, a small 5 mm seed transforms into a majestic plant, proudly standing two meters high and which generously supplies 2.3 m2 of tobacco.

The Harvest

The harvest begins in January and extends for some weeks. The tobacco is picked by hand in six passages, each of which takes about seven days. The harvest begins at ground level and moves upward, removing only two or three leaves per passage. About 120 days pass between the transplantation of the seedlings to the end of the harvest; during this time each plant has be examined 170 times on average – an extremely labor-intensive affair.

Corojo-Ernte

The Corojo Harvest

The uppermost leaves of the plant, the “Semi Corona” and “Corona” deliver the exceptionally aromatic and full-bodied parts for cigar production. In “Centro” one finds the most beautiful and finest of leaves with a balanced flavor. The best leaf quality is found in the “Centro Fino”. The aromatically less distinctive, lower leaves on the plant are called the “Libre de Pie” and “Uno y Medio”; they display especially fine burn characteristics.

The Criollo Harvest

The Criollo plant carries six or seven pairs of leaves, which are divided into the classifications Ligero, Seco, Volado und Capote. The younger leaves at the top which are exposed to sun, have a stronger flavor and a higher nicotine content. The Seco leaves from the center of the plant are somewhat milder. The bottom leaves, exhibit the least flavor, as they are the oldest and have had the most shade. They are primarily used as filler.

Air-drying

The bundled leaves are brought into the drying sheds (Casas del Tabaco) to dry. These are aligned on an East/ West so that the sun warms one end of the shed in the morning and the other in the afternoon. Temperature and air humidity are carefully regulated by opening and closing doors located at both ends. The tobacco leaves are attached in pairs by way of needle and cord to wooden poles (Cujes or Poles), which are hung just above the ground. During the drying process which takes about 50 days, they are gradually hung higher and higher in the shed. The leaves first turn yellow and then through the oxidation process, take on their famed golden brown color.

The First Fermentation

The tobacco leaves are packed together into bundles (Gavillas) and then moved into the fermentation house. Here they are stacked in piles (Pilones), reaching over three feet high. If the temperature of the tobacco rises above 35°C, the piles are dismantled and allowed to cool until they can again be heaped up. The first fermentation lasts about 30 days, within which the leaves take on an even color, resins are reduced, and ammonia and other unwanted components are dissipated.

De-ribbing and Sorting

The tobacco leaves are moistened with water in order to avoid discoloration. Subsequently the main ribs are removed. The leaves are then sorted, depending upon intended purpose, color, size and quality. The complete de-ribbing and final sorting in up to 50 different categories takes place much later in the factory.

The second Fermentation

The leaves are again bundled together and stacked into meter-high piles (Burros). The tobacco goes through a chemical change which positively influences its taste and flavor, and allows any remaining foreign components to diminish. The second fermentation is stronger than the first and lasts up to 60 days. The wrappers undergo the shortest fermentation.

Storage

After resting for some days on ventilation racks, the tobacco is pressed into bundles called “Tercios”, which are wrapped in palm bark or banana leaves. These bundles are delivered to local collection points, which are under the control of the state monopoly HABANOS. From this moment on, the Republic of Cuba assumes responsibility over the further treatment of the tobacco. The Tercios are kept up to three years in depots – for some formats even longer – until they are needed by the cigar factories. The taste and flavor of the tobacco continues to improve during this storage period.

The Preparation of the Tobacco

The wrapper leaves are moistened so that they are supple and smooth; afterwards they are hung up over night so that the humidity can distribute itself evenly along the leaf. The next day “Despallidores” remove the central ribs by halving the tobacco leaf. Next the leaves are sorted by the “Rezagadoras” into piles by size, color and structure. The binder and filler do not require humidifying. The various types of leaves have different ripening intervals; the blending master attentively supervises the development of each sort. Subsequently, the leaves go to the blending station, where under strict safety precautions the blending process takes place. It is here that the carefully guarded secret recipes for each Habanos are kept. The mixtures are handed out to the cigar rollers (Torcedores), the amount of which is just enough for the production of 50 cigars.

The Production of Cigars

At the heart of each factory is the “Galera”. It is here that the Torcedores create the various sorts and formats. The only tools employed are a wooden table, a sharp blade (Chaveta), a guillotine, a small pot of vegetable adhesive and – above all –skillful fingers. Each Torcedor is able to daily roll about 120 cigars which perfectly keep to the prescribed lengths and diameters. Samples of their work are regularly examined by quality testers, and should the cigars not be found good, this is very serious affair for the Torcedor as they are paid by the piece.

The Escaparate

Directly from the work bench, the cigars are delivered to a climate-controlled room, the “Escaparate”, which is equipped with high cedar wood shelves. For at least three weeks and sometimes for several months, the finished cigars are stored here under ideal conditions: The temperature lies between 16°C and 18°C and the relative humidity between 65% to 70%.

Color Determination and Attachment of Cigar Bands

In order for a perfect presentation of the cigars, the Escogedor (color sorter) sorts them into 65 different shades of color. A second Escogedor arranges the cigars into boxes so that the color tones from dark to light are presented from left to right. He also chooses which side of the cigar will be displayed when the box is opened at a later date. The Escogedores belong to the best paid workers in the factory.

The Anilladora (bander) removes the cigars from the box in order to attach the bands. Under no circumstances may she change the arrangement selected by the Escogedor nor the side of the cigar to be displayed. The packed boxes are now secured with the guarantee seal of the Cuban government. The crates are made of cedar so that the cigars can breathe and mature further. After a production process spanning several years, the Habanos are now ready for their journey to foreign lands, where they are blissfully awaited by connoisseurs.

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The Cultivation of Tobacco and the Production of Cigars

The Cultivation of Tabacco