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Every cigar
that is lit somewhere in the world has behind it a long story to tell. And it is
so because, from the moment when the seed is planted until it is ready to be
offered to the consumer, a long time elapses and numerous and varied processes
occur, in which dozens of people have intervened who offer the best of
themselves to produce a product, which is, perhaps, the most handmade and
natural of all the consumable products that exist.
This long
journey begins with the selection of the seeds and the sowing of the plants in
seedbeds, where they are left until they reach a few inches in height, at which
time it is proceed to transplant them to the field. Once that between 40 and 50
days have passed since the transplant, the recollection of the leaves begins.
This slow and laborious process can take up to 30 days from the beginning,
because each type of leaf has a different recollection time, in addition to the
fact that all leaves must be harvested by hand to prevent deterioration.
The harvest
has finished and a long journey has begun during which the leaves, after going
through three key processes, will have undergone important transformations:
curing (some call it drying), fermentation and aging. Only after these complex
and time-consuming processes have been completed will the sheets be ready for
cigar making, which involves many laborious activities and phases.
The curing
of the leaves, which generally takes between 40 and 50 days more, is a process
where important biochemical and above all physiological transformations take
place, some of which are internal and therefore not visible and others can be
observed with the naked eye. This process is also known as drying but in
reality it would be applicable to curing that is carried out artificially,
because in the manual, the biochemical transformations of the leaves
predominate over the loss of water.
After the
leaves are cured, fermentation begins, which is also a natural process in which
the physical-chemical properties of tobacco are altered through enzymatic
transformations. This process is essential for tobacco production, as it not
only removes harmful ammonia compounds from tobacco, bacteria, microorganisms
and molds, but also improves the quality of the tobacco and ensures that the
leaves develop with the correct softness and aroma.
If carried
out under suitable conditions, it is a guarantee of obtaining a high quality
tobacco with the characteristic color, aroma and flavor of a certain variety.
The duration of this process will vary according to the humidity and
temperature conditions at which it is carried out, but in general terms, no
less than 30 days should elapse before the tobacco is considered ready for
classification.
Once the
fermentation time is over, the leaves are packed to begin the long final
process that is aging, through which a slow and constant decomposition of
carotenoids occurs, key to highlighting the desirable properties of tobacco.
For stronger leaves, this period can take up to two and more years. In any
case, it is important to note that, as for a good wine, the longer a leaf
matures, the higher its quality.
When the
aging is finished, the leaves are ready to become cigars, although it should be
noted that after the cigar is in the hands of the consumer, they may decide to
age it even more, for which special devices called humidors are used, by means
of which it is possible that the cigar continues to evolve, over time, in
flavor and aromas.
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