Discover the secrets of tobacco curing and fermentation, fundamental steps in the creation of top-of-the-range cigars. There's an old adage in the cigar world: "It takes 300 hands to make a cigar". Before arriving on your retailer's shelves, each tobacco leaf undergoes a series of meticulous transformations, aimed at revealing its unique aromas and guaranteeing perfect combustion. Among these stages, the fermentation and curing processes play a fundamental role. They transform raw tobacco leaves into a refined product that meets the quality requirements of premium cigars. In this article, we take an in-depth look at the importance of curing and fermentation in the production of exceptional cigars.
The first step: curing the tobacco
Tobacco curing is the stage that takes place just after the leaves have been harvested. During this phase, the leaves are carefully dried to eliminate excess moisture and enable the chemical composition of the tobacco to be modified, while preserving its physiognomic properties.
The main curing
Curing methods vary according to the type of tobacco and the objective sought. The most common methods include :
- Air drying : This natural drying method is widely used in the manufacture of premium cigars. It involves exposing the leaves to the open air and out of the sun, usually in wooden barns. The tobacco is then cured slowly, over a period of 4 to 12 weeks, which is essential to prolong the drying process to completion and ensure slow oxidation of the plant tissues. This method significantly reduces the sugar content of the tobacco, resulting in tobacco leaves with lighter flavors and higher nicotine levels.
- Fire drying : In this method, the leaves are exposed to the heat of a fire for between 3 days and 10 weeks. This process produces powerful tobacco with smoky, woody notes, low sugar content and high nicotine levels. It is rarely used for high-end cigars, as it generates a distinct smoke that influences the taste of the tobacco.
- Sun drying: This natural curing process exposes the leaves to direct sunlight for 2 to 4 weeks. Mainly used in Asian and Mediterranean countries, it produces tobacco leaves with a high sugar content and lower nicotine levels, offering smoother, more balanced flavors.
Influence of curing on the chemical composition of tobacco
The curing process brings about several changes in the chemical composition of tobacco leaves. In the initial phase, chlorophyll degradation breaks down the sugars, proteins, starch and nicotine present in tobacco. In contact with air, the leaves oxidize and gradually lose their green hue, turning first yellow, then brownish.
When the leaves have lost around 80% of their moisture, they are sorted according to weight and size, then lightly moistened (to the tune of 18 to 25 % of their weight) before being placed in bundles of around fifty leaves. At this stage, the plant cells are dead, but the enzymes remain active and continue to bring about chemical transformations in the tobacco leaf.
The second stage: tobacco fermentation
Fermentation is a decisive stage that refines tobacco aromas and develops its color. It occurs naturally, thanks to the heat and humidity created by storing the leaves in piles. Unlike alcohol fermentation, tobacco fermentation does not produce new by-products, but eliminates impurities such as ammonia, while developing the tobacco's aromas and flavors.
Tobacco fermentation generally takes place in several phases, each with a different duration and intensity, depending on the type of leaf and the result sought by the manufacturer. It's important to note that fermentation is as much an art as a science. Although there are general principles, each manufacturer adapts the fermentation process according to the type of tobacco. type of tobacco and the desired aromatic profile.
The firstère fermentation
The first fermentation begins after curing and generally lasts between 30 and 40 days. During this stage, the leaves are stacked on top of each other to form "gavillas". These stacks are then covered with a fine cloth to promote air circulation. This complex process accelerates the degradation of the micro-organisms contained in the leaves, thanks to the spontaneous heating produced by the compression of the leaves. The temperature is regularly monitored, because if it exceeds 35°C, the leaves will spoil and lose their flavor.
When the temperature in the center of the gavillas reaches the desired threshold, they are carefully unwrapped and rebuilt according to a precise pattern. The leaves in the center are moved to the top, those at the top to the bottom, and those at the bottom back to the center. This process is repeated until all leaves have been uniformly processed. On average, tobacco stacks need to be transplanted 5 to 8 times throughout the fermentation process to ensure even distribution of heat and humidity.
Leaves fermented at the end of this first stage are generally more uniform in color and have a milder flavor profile. However, they are not yet ready for use in cigars. They are first trimmed to remove the midrib, then sorted and graded according to use, size, texture, shade and quality. Only the best leaves are kept to make the tripe. They are then gathered into bales before undergoing a second fermentation phase.
The secondème fermentation
The second fermentation is longer and more intense. The leaves, now sorted and moistened, are grouped into burrosThese are massive heaps of tobacco that can weigh up to 2,000 kg. Fermentation generally lasts between 60 and 90 days, depending on the intensity of the desired flavor, and the temperature is rigorously monitored to never exceed 42°C.
During this stage, the leaves undergo a further chemical transformation. Ammonia is eliminated, and certain aromas develop in a more pronounced way, such as woody, herbaceous and toasted notes.
The thirdème fermentation: a rarer process
Third fermentation is a rarer process, but one that has been adopted by some high-end cigar brands, such as Cohiba. This process takes place in temperature-controlled casks and adds further complexity to the tobacco's flavor profile.
Influence of fermentation on the chemical composition of tobacco
Fermentation transforms the tobacco into a milder product, with improved texture and more subtle aromas. During this stage, the tanninscompounds responsible for tobacco's astringency, break down, reducing the bitterness of the leaves and producing a uniform brown color. In addition, the sugar contained in tobacco is transformed into organic acids or volatilized in the form of carbon dioxide and water. This change contributes to the tobacco's sweetness and improved taste.
In terms of flavor, fermentation eliminates unpleasant vegetal aromas, often compared to those of cucumbers, to make way for more complex, deeper flavors. This change in flavor is influenced by the breakdown of proteins and the reduction of nicotine during fermentation.
Ageing and maturation of the tabac
©Davidoff
After fermentation, tobacco leaves can be stored for extended periods to undergo further maturation. This aging process, or añejamientoThis allows tobacco to continue evolving slowly, even after it has been rolled into a cigar.
Aging allows further refinement of tobacco flavors and add further complexity, giving cigars a more nuanced taste. Aged cigars become less harsh and richer, their aromas blend better and new, more subtle notes can emerge.
Conclusion
Curing and fermentation are essential steps in the production of premium cigars. These meticulous processes, which combine craftsmanship and scientific precision, transform raw leaf into a refined product, rich in flavor and nuance. While curing preserves the integrity and aromatic potential of the tobacco, fermentation refines its characteristics by reducing bitterness and developing complex aromas.
These stages require patience, expertise and precise control of temperature and humidity. They highlight the complexity of tobacco preparation and the delicate balance required to produce high quality cigars. Understanding the importance of curing and fermentation allows connoisseurs to better appreciate the art behind each premium cigar.
FAQ
Curing is the process of drying leaves after harvesting. It reduces their humidity, modifies their chemical composition, and preserves their properties. It's a key stage in guaranteeing the unique aromas and perfect combustion that are essential for premium cigars.
Air drying Favors light flavors, ideal for high-end cigars.
Fire drying Produces a tobacco with smoky notes, less used for premium cigars.
Sun drying Gives sweet, balanced flavors, used in specific regions.
Fermentation is a natural process in which heat and humidity eliminate impurities (such as ammonia) and develop aromas. It transforms vegetal flavors into complex notes such as woody, toasty or herbaceous, essential for quality cigars.
The curing is the initial drying phase that prepares the leaves, while the fermentation refines aroma and texture by reducing impurities. These two stages complement each other to produce premium cigars.
Aging allows tobacco to continue maturing slowly, refining its aromas and softening its taste. This process gives cigars a rich, nuanced character appreciated by connoisseurs.
