From Seed to Smoke: The Journey of a Perfect Cigar Leaf
- Jan 19
- 4 min read
It is quite clear that cigars are rolled using aged tobacco. This gives the cigar a distinct difference in taste and appearance from regular cigarettes. With this information, how are tobacco leaves sorted and aged after harvesting? But first, let us look at the growth process.
The tobacco growing process begins with germination from seeds in a controlled environment, typically in seedbeds. After 4-8 weeks, seedlings are transplanted into prepared fields. During the growth phase, which lasts about 90-120 days, plants require regular watering, fertilisation, and pest management. They grow to heights of 3-6 feet, developing broad leaves. As the leaves mature, they change color and texture. Harvesting occurs when the leaves are fully mature, usually in late summer to early fall. The leaves are then cured to enhance flavour and quality before processing for consumption.
While it seems like a no-brainer that tobacco leaves are sorted before being used to create your cigar, it may amaze you the number of times that tobacco is sorted before it is eventually used. Some tobacco factories sort their tobacco as many as 5 or more times! Let us take a look at when and why the tobacco is sorted…
Pre-Hanging Sorting
Before tobacco is hung in a curing barn, it is sorted by a variety of tobacco as well as size and priming. In some cases, certain tobaccos even have their curing barn (such as with the Davidoff Royal). The leaves are also sorted by size so that leaves of similar sizes are arranged stem to stem. This is done to allow maximal airflow and prevent the growth of mold as the leaves dry out. Also, within the barn the tobaccos are arranged by priming as well, this is because higher primings of tobacco are thicker and take longer to dry out.
Post Curing Sorting
After the tobacco leaves are done hanging, they are roughly sorted by leaf quality. These are looking for obvious flaws in the leaves that will prevent them from becoming wrappers. Damage can happen in many ways in the fields and barn (such as someone walking into the plant etc). Any holes will prevent the leaves from being used as a wrapper. The tobacco leaves are then placed into Pilons for fermentation based on the quality of the tobacco as well as the priming. Pilon is a large pile of tobacco leaves arranged to aid in the fermentation process. The tobacco leaves can stay in pilons for as long as 10 years or more depending on the specification set by the manufacturing plant.
Post Fermentation Sorting
Once the tobacco leaves are done fermenting in the Pilons they are again sorted for quality purposes. This time not only are the leaves judged for any damage to the leaf, but also any discolouration that may have occurred during the natural fermentation process. While the Pilons are turned and leaves rotated several times during the fermentation process, some leaves are left with uneven color. Tobacco that is used for binder typically has some slight discolouration or very minor damage to the leaf. Also, sorters are looking for any water spots that might have occurred during the fermentation process.
“Low Inventory” Sorting
At the beginning of the cigar manufacturing process, wrapper standards are very high, taking only the very best of the leaves for wrappers. Later, when a manufacturer is running low on wrappers or binders, sometimes they will do a secondary sorting of the tobacco. This is most common with wrappers, but can also occasionally happen with binder leaves. This secondary sorting is looking for any binder leaves that have minor flaws that can be instead used for wrappers (while working around flaws obviously) or filler leaves that are large enough to be used for binder purposes. Rest assured, manufacturers do not put out cigars with wrappers that do not meet their standards!
Color Sorting
The final sorting occurs after the cigars have been rolled and before they are put into boxes. Cigars are arranged on a table before being placed in a box, this is to minimize the small colour difference that occurs naturally in the wrapper leaf. Traditionally, this final sorting is done only by women, who have a better eye for colour differences. Any cigars that are significantly off by colour standards are then discarded.
The Cigars Rolling Process: A Craftsmanship Tradition
The process of rolling a cigar is an intricate art that requires skill, patience, and attention to detail. It begins with the selection of tobacco leaves, which are carefully grown, harvested, and fermented to develop their flavours. The leaves are then classified into three categories: the filler, binder, and wrapper.
Filler: The core of the cigar, made up of long or short tobacco leaves, is carefully blended for flavour and strength. The filler is the most important component in determining a cigar's taste.
Binder: The binder is a tobacco leaf that holds the filler leaves together. While it doesn’t influence the flavour as much as the filler, it is essential for ensuring the cigar burns evenly.
Wrapper: The wrapper is the outermost leaf, prized for its smoothness and appearance. It affects the flavour and the overall smoking experience, so it must be carefully selected for quality and texture.
The rolling process itself is a delicate procedure, usually done by hand. A skilled torcedor (cigar roller) arranges the leaves, rolls them tightly but evenly, and carefully seals the edges. The finished cigar is then aged for a period before it is ready for consumption.
The entire process, from selecting the leaves to rolling the cigar, requires precision, expertise, and passion which ensures that each cigar is a product of true craftsmanship.
It is through this process that all of the major cigar manufacturers go through to ensure the craftsmanship and quality of the products is maintained. Now whether it is a Cuban, Nicaraguan or Dominican Cigar, be sure to scan through the website to view what might be interesting to you.
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