Let’s examine the life cycle of a cigar, from its humble beginnings as a tobacco seed to its final resting place in a cedar box.
The Foundation of Flavor
The journey of a cigar begins with a tiny seed, planted in nutrient-rich soil. The seed determines the size, color, texture, and type of plant, while the soil and climate influence the taste, aroma, and burning qualities of the final product.
From Nursery to Field
In September and October, pinhead-sized tobacco seeds are sown in protected seedbeds. After about 45 days, the seedlings are carefully transplanted to the fields, where they will grow under the watchful eyes of farmers.
Harvesting and Priming
The Art of Leaf Selection
As the tobacco plants mature, they undergo a process called priming, where leaves are carefully harvested. The three types of leaves – Volado, Seco, and Ligero – each have unique characteristics that contribute to the cigar’s flavor and strength.
The Three Types of Leaves
Volado-the mildest of the leaves in taste
Seco-a medium flavored leaf, which comprises the largest middle portion of the tobacco plant
Ligero-the strongest in taste.
Thus, the closer you get to the top of the plant, the thicker the leaves and the heavier the taste. Normally, it takes a blend of all three of these leaves, in varying proportions to make a cigar.
Fermentation and Aging
Transforming Tobacco
After harvesting, the tobacco leaves undergo fermentation. This process involves stacking the leaves in large piles, known as bulks, where they “sweat” and release moisture. Fermentation helps to develop the tobacco’s flavor, aroma, and color.
Curing and Drying
The Dance of Air and Leaf
The fermented leaves are then hung to air-cure in barns. Over several weeks, the leaves lose their moisture content and gradually change color from green to brown. This natural curing process is essential for developing the tobacco’s final character.
Sorting and Grading
The Pursuit of Quality
Once cured, the tobacco leaves are meticulously sorted and graded by size, texture, and color. This ensures consistency and quality in the final product. Only the finest leaves will be selected for use in premium cigars.
The journey of a cigar, from the seed to its final form, is a testament to the intricate process and the dedication of those involved in its creation. Each step, from planting and nurturing to harvesting, fermenting, and curing, plays a crucial role in shaping the cigar’s unique character and ensuring its quality.
