How cigars are made
Behind the Scenes: How Cigars Are Made
Steeped in tradition and enjoyed across the world, each cigar is a testament to the art of tobacco craftsmanship. From the careful selection of leaves to the final wrap, the cigar-making process is rich in history and complexity. In this post, we will explore the fascinating journey of how cigars are made, uncovering each step from the tobacco fields to the finished product. Whether you’re a seasoned aficionado or new to the world of cigars, understanding how cigars are crafted can greatly enhance your smoking experience.
The Process from Leaf to Lounge
Step 1: Cultivation of Tobacco
The first step in the making of a cigar is the cultivation of tobacco plants. The type of leaves used for cigars varies, with the most common being Nicotiana tabacum. The soil and climate of regions like Cuba, Nicaragua, and the Dominican Republic are ideal for growing different varieties of tobacco plants that ultimately define a cigar’s flavour profile.
Step 2: Harvesting
Tobacco leaves are harvested either by hand or using machinery, depending on the size of the plantation. Leaves are picked at precise times during the growing cycle to ensure optimal maturity and flavour. The bottom leaves (volado) are usually harvested first, followed by the middle (seco), and finally the top leaves (ligero), which receive the most sunlight and have a robust flavour.
Step 3: Curing
After harvesting, the leaves undergo curing, a process that involves air-drying the leaves in a controlled environment. This step is crucial as it reduces the leaf’s chlorophyll content and brings out natural sugars, influencing the colour and taste of the leaf. Leaves are hung in curing barns where the humidity and temperature are carefully controlled.
Step 4: Fermentation
Fermentation is a critical step that further develops the tobacco’s flavour. The cured leaves are moistened and stacked in bulks or piles. Heat builds up within the pile, fermenting the tobacco naturally. This process can take a few weeks to several months, depending on the type of tobacco and the desired end flavour.
Step 5: Aging
Once fermentation is complete, tobacco leaves are aged. During aging, the flavours mellow, and the harshness of the tobacco diminishes. Aging can last from two years to several decades. The duration of aging significantly affects the quality and flavour profile of the final cigar.
