In this blog we will give an introduction into the Finer points of Cigar smoking and the lifestyle around it. we dig into the enthralling world of handcrafted tobacco delights. In this blog article, we will delve into the complexities of cigars, from their origins and creation to the various flavours and immersive sensations they provide. So sit back, relax, and prepare to go on an incredible adventure through the fascinating world of cigars.

1. A Glimpse of Cigar History:

Cigars have a long and illustrious history that dates back centuries. Cigars, which originated in the Americas and expanded throughout the world, have become an iconic symbol of elegance, sophistication, and indulgence. We'll look at the history of cigars, beginning with the indigenous peoples of the Caribbean and ending with the discovery of tobacco by European explorers.

2. The Craft of Cigar Making:

Making cigars is a precise art form that necessitates talent, expertise, and attention to detail. We'll go over the numerous phases of making a perfect cigar, from selecting premium tobacco leaves to the careful rolling process and ageing. below is a more in depth guide to the process of Cigar making emphisizing on the importance of tobacco kinds, fermentation procedures, and master blenders in developing distinct and harmonious flavour profiles.

Tobacco farming

There are only a few areas in the globe that give optimum growing conditions for tobacco. An ideal soil and seeds serve as the foundation for any successful cultivation. The first saplings are bedded down around two weeks after seeding begins in mid-September. Wrapper plants mature in about 90 days, whereas fillers require 50 to 70 days.

To regulate temperature, humidity, and sun exposure, gauze sunscreens are spread throughout the tobacco fields. 

The growth of the tobacco leaves is continually monitored. To get the appropriate quality, the leaves must be collected on the day. 

Tobacco leaves or primings are classified into three types: 

The lower leaves are known as "Volado" and are the mildest sort of leaf. The centre leaves, known as "Seco," have a powerful flavour, whilst the top leaves, known as "Ligero," have a more refined taste and texture.

Tobacco Harvest

Harvest starts in January and ends in April. During a single harvesting session, two to four leaves from each plant are typically collected.

Because a tobacco plant has 16 to 18 leaves, it can produce up to six harvests in a single season.

Overall, it takes around seven months from bedding out the saplings to the final harvest.

Drying and Fermentation

The Drying

After picking, the leaves are sorted by size and structure, joined together in pairs, and hung over poles in an orchard house. During the drying process (which takes a few weeks), the moisture content of the leaves diminishes, and oxidation causes them to transform from green to brownish. The time required to dry tobacco leaves varies depending on their subsequent usage in the production process (wrappers, fillers, or shortfillers).

The First Fermentation

After being separated by size, the leaves are further split by colour and placed in "burros" before the first fermentation, which is similar to composting. Heat is generated inside these stacks, and the temperature must be carefully monitored. The period required for drying and fermentation varies according to the type of leaf and might range from 25 to 60 days. The initial fermentation reduces the concentration of resin and provides the leaves an evenly dispersed hue.

The second fermentation

After sorting the leaves again by size, colour, and structure, they are soaked with a water-tobacco juice solution. A second fermentation begins, during which acidity, tar, and nicotine levels are reduced as the tobacco's flavour spreads throughout the leaves. They are then wrapped in palm or banana leaves and shipped to various cigar manufacturers.

The Third Fermentation

In the factory, the leaves are separated into wrappers, long fillers, and fillers. Wrappers and lengthy fillers are treated mechanically or manually. The third fermentation, which precedes tobacco mixing, might take up to ten years for Premium tobaccos. During that period, the leaves are carefully stored in wooden barrels while being ventilated.

Processing and Blending

Blending is the practice of merging leaves from different plantations in such a way that the aroma and flavour remain consistent year after year while ensuring quality. Only the specific blend gives a cigar its distinctive scent. The recipes are the cigar manufacturers' most carefully guarded secrets.

Rolling A Cigar

Depending on the format, two to four tobacco leaves are hand folded over each other to make a conical shape. This creates ventilation canals inside the cigar, ensuring an equal draw.

Next, the filler is folded into one half of the binder; bigger sizes require two halves. The resulting cluster is then pressed into a wooden frame.

The cigarmaker now removes one of the soaked wrappers, unfolds it on his cutting board, stretches it, and cuts it to size. The bunch is now gently placed in an angle position on the wrapper and carefully wrapped.

In the next phase, a spherical piece is cut from the remaining wrapper leaf and applied to the cigar's head using a natural glue. Some cigars' heads are formed by twisting the wrapper's ends together.

The cigarmaker then strokes his blade over the wrapper before rolling the cigar on his table to polish it up. The final step is to reduce the cigar to its desired length.

The Final Steps: Rest Period

The handmade cigars are bound into a batch of 50 pieces. These batches are stored in a special smokebox to avoid vermin damage. 

Then they are stored in cedarwood cabinets for up to eight weeks. In this step, a portion of the moisture absorbed by the cigars during previous steps is removed, the fermentation process is completed, and the tastes of the various varieties of tobacco are combined together.

Quality Inspection

Following the rest period, a sample from each batch is withdrawn for quality inspection, which includes length, diameter, weight, workmanship, and appearance. 

Test smokers evaluate the cigar's flavour, burn-off, and draw. The cigars are then sorted by major colours and subsequently by varying tints of the same colour, allowing each box to contain the same colour cigar.

Boxing and Quality Seal

The cigars are now sorted by colour and given a band, which is manually bonded to the cigar with a natural adhesive.

Cigar boxes are typically made of cedarwood, which aids in the ripening process and prevents the cigar from drying out. 

After the boxes are embellished with creative embellishments (brand initials and pictures), the cigars are placed inside, covered with a thin sheet of cedarwood, and the box is closed and sealed with quality seals from various cigar manufacturers.

3. Unravelling the Flavours:

A Senses Journey: Cigars come in a variety of flavours and scents, making each smoking experience a sensory adventure. We'll look at a variety of flavour profiles, from light and creamy to powerful and assertive. Learn about the characteristics of various tobacco regions, the effect of ageing on flavour development, and how mixing techniques help to create nuanced and pleasant cigars.

4. Investigating Cigar Traditions and Rituals:

Cigars are steeped in tradition, and many rituals add to the charm and enjoyment of the experience. Learn the significance of cutting and lighting procedures, the art of ashing, and how to enjoy a cigar properly. We'll also look at the social sides of cigar smoking, such as cigar lounges and clubs, as well as the companionship that frequently comes with this shared love.

5. Pairings, Accessories, and Travel in the Cigar Lifestyle:

Embracing the cigar lifestyle entails more than just smoking. We'll look at how to combine cigars with drinks like whisky, rum or coffee to enhance the flavour and create a harmonic experience. In addition, we'll feature crucial cigar accessories, such as humidors and cutters, as well as lighters and ashtrays, as well as prominent cigar destinations, such as tobacco plantations and renowned cigar festivals. Conclusion: Cigars provide a world of sensory pleasures, cultural traditions, and relaxing moments. Cigars have captivated connoisseurs for years due to their rich history, precise craftsmanship, and distinct flavour characteristics. Exploring the world of cigars, whether you're a seasoned aficionado or a curious newbie, is a voyage that promises to excite the senses and provide an escape into a realm of exquisite enjoyment. So, fire your enthusiasm for cigars, embark on an enthralling journey, and taste the unforgettable pleasures that await you. At Churchills Tobacconists, we provide a wide selection of cigars and accessories to suit everyone from the seasoned aficionado to the inexperienced beginner. Subscribe to our newsletter to get more information, and we hope to see you soon. Best wishes Codie