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&

Lesson - 5

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Aims & objectives:- at the end of this chapterstudents should understand the basics of following

points-

Cigars & cigars

Manufacturing of cigars

Cigar strength,type,flavor,popular brands, cuts

Service of cigars

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INTRODUCTION

Cigar smoking is a culture in itself. pipe smoking (one ofthe most common form of smoking) is considered now,of early period, old fashioned and also regarded as anantique,unsusual in present scenario.

Cigarette smoking began popularized in 19th centurywhen industrial revolution took place. This revolution ledto many factories, machines and automation in general.

Hence cigarette production became popularized.

Cigars have been and still are taken as a symbol formasculinity, power and big capitalists.

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CIGARS

A cigar is a tightly bundle of dried and fermented

tobacco which is ignited so that its smoke may be inhaleinto the smokers mouth.

Its a cylindrical roll of tobacco consisting of cut tobaccoFiller formed in a binder leaf and with a wrapper leaf

rolled around the bunch(filler + binder).

The most expensive leaf used in cigar is wrapper leafmust be Strong ,elastic ,silky in texture, and even in

colour. Should have a good burning quality and pleasantflavour.

Cigars are bigger than cigarettes and the odour and

smoke they produce are stronger and pungent.

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CIGARETTE

A cigarette is a tobacco product consumed through

smoking And made with cured and finely shreddedtobacco leaves often combined with other additives,then rolled or filled/stuffed into a paper rolled cylinder(generally less than 120 mm and 10 mm in diameter.

The cigarette is ignited at one end and allowed tosmolder for the purpose of inhalation of its smoke fromthe other (usually filtered) end.

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A cigarette is distinguished from a cigar by-

Its smaller size.

Use of processed leaf (cured & fermented)

White paper (generally) roll or wrapping

Cigars are typically made entirely of whole leaf tobacco

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MANUFACTURING OF CIGARS

1.Cultivation of tobacco:-

Tobacco plants are seededindoors, and then transplantedInto fields after 6 to 10 weeks.The plants are carefully pruned

so that the leaves grow to thenecessary size.

Plants which produce cigar

wrappers are kept covered withcloth to protect them from sun.

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2.Curing

After harvesting, tobacco leaves

are cured to develop theirAroma,flavour and otheressential aspects.

Leaves for curing are pickedfrom plant when these leavesare ripened means when leavescolour vary from bright green to

brown or yellow.

Chemically, here chlorophyllgradually breaks down and is

replaced by carotenoids.

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Fermentation process-

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3.Fermenting -

Cured leaves are sorted by colour and size at thisstage. Small or broken leaves are used for the cigarfiller, large leaves for binder and large fine leaves forouter wrapper.A bundle of 10 15 leaves are made which is called

hands. hands are packed in hogshead (large casks) orin boxes. This process is called fermentation wherechemical changes occur to leaves and this takes timefrom to 6 months to 5 years.2 to 5 yrs fermentation is

required for high quality cigars. During fermentation,aroma and taste of the leaf develops. This leaves areagain sorted now.

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4.Stripping -

The stem or main vein of the filler leaves should be removedso the cigar can burn evenly. this can be done by both

manually or mechanically.Manually, a worker with a thimble knife fitted to his/her finger,clips the vein near the tip and pulls it down. then these leavesare stacked in piles (bundles) called books or pads

Mechanically, a worker inserts the tobacco leaves into amachine under a grooved, circular knife. by depressing afoot treadle( a lever moved by foot & imparting motion tomachine), the worker causes the knife to lower and cut out the

vein. Then these leaves are stacked.

The stripped leaves are wrapped in bales(bundles) and storedFor further fermentation. Just before the leaves are ready formanufacture, they are steamed to restore lost humidity and

sorted again.

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5.Hand rolling -

Cigar rolling is a skilled work. the filler must be packed

evenly to make the cigar burn evenly & smoothly. thewrapper should be bound in an even spiral around thecigar.

Each worker sits at a small table with a tray of sortedleaves and some space for rolling. first 2-6 leaves areselected for the filler and are placed one on top of theother. now these are rolled and placed on the binder

leaf and again rolled around the filler.

These partially completed cigars are placed in an openmould which keeps them in shape until they can be

wrapped.

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chaveta

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PLACING BANDS

CIGARS OPEN END (FOOT)

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HAND ROLLING OF CIGARS

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HAND ROLLING OF CIGARS

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6.Wrapping -

Wrapping is most significant and difficult task. it requireA worker to be very efficient.The worker places the uncompleted cigar on wrapperleaf. with a special knife(chaveta) he trims off anyirregularities from the filler.then the worker rolls the

wrapper around three and a half time, and secures it atthe end with a small amount of vegetable paste(either anatural tobacco paste or a mixture of flour and water).This is done by cutting a small round piece out of a

different wrapper leaf and this piece is then attached tothe end of the cigar with paste.Now the cigar is complete but it still must be tested,sorted and packed.

7 hi lli

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7.machine rolling -

Maximum cigars are made by machines today. a machinemay require several workers to perform its various functions.

one worker feeds tobacco leaves onto a belt between guidebars that can be adjusted to the required cigar length.machine makes the bunches for filler. second worker placesbinder leaf onto the binder die. The machine rolls the binder

around the filler. a third worker places the wrapper leaf on awrapper die. now the partially completed cigar drops onto thewrapper die, and the machine rolls the wrapper around thecigar.

Fourth worker inspects the completed cigars and placesthem in trays.After this the examiner checks all cigars for imperfections andthem for weight, size, shape and condition of the wrapper. theexaminer may correct imperfections by patching wrappers or re-

shaping heads (final quality control)

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8.Finishing & packing

After passing the quality checks, these ready cigars areplaced on trays and passed to banding and wrappingmachine.

These cigars are then are put into a hopper( a funnel

like device) where the machine places a band aroundthem. The same machine may be used to wrap thecigars in cellophane.

Then again these cigars can passed to specialists whosort out these according to minute colour variation andfinally boxed together.

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9.Quality control -

Cigars are checked at each step of manufacturing forquality. quality of tobacco leaves is very important, sothe leaves are sorted and inspected after curing,fermentation and processing.

Finished (ready) cigars must be checked foreven/consistent diameter, weight, size and otherimperfections in the wrapper or in shape.

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CIGAR STRENGTHThe wrapper determines much of the cigars character andflavour. Its colour is often used to describe the cigar. Colours

are designated from lightest to dark-TERM DESCRIPTION

Double Claro

very light, slightly greenish also called candela or jade);achieved by picking leaves before maturity and dryingquickly; the color coming from retained green

chlorophyll ; formerly popular, now rare.Claro light tan or yellowish, indicative of shade grown tobacco

Colorado reddish-brown (also called rosado or Corojo)

Colorado Claromid brown; particularly associated with tobacco grownin Cuba

Colorado MaduroDark brown; associated with Honduran or Cuba growntobacco

Natural light brown to brown; generally sun grown

Maduro Dark brown to very dark brown

Oscuro(doublemaduro)

Black; often oily in appearance; mainly grown incuba,brazil,mexico,USA

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CIGAR STRENGTH BY WRAPPER COLOUR

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Some manufacturers use an alternate designation -

TERM DESCRIPTION

American MarketSelection (AMS) synonymous with double claro

English MarketSelection (EMS)

can refer to any colour stronger than doubleclaro but milder than maduro

Spanish Market

Selection (SMS)

either of the 2 darkest colours, Maduro &

Oscuro

C Colorado - A dark & strong cigar

C.C Colorado Claro - medium cigar

C.C.C or C.M Colorado Maduro - A very strong cigar

M Maduro - An exceptionally strong cigar

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In general, dark wrappers add a touch of sweetness,while light ones add a hint of dryness to the taste. It iscommonly accepted that the wrapper contributes about

40 percent of the flavor, while the filler and bindercontributes the other 60 percent. It is generally acceptedthat maduro cigars are stronger in flavor than the samecigar in a lighter wrapper, but this does not apply to all

cigars.

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CIGAR TYPESCigars are commonly categorized by the size and shapeof the cigar, which together are known as the vitola.

The size of a cigar is measured by two dimensions: itsring gauge (its diameter in 64th of an inch) and itslength( in inches)

All cigars can be divided into two broad categories:(1)parejosand (2)figurados.Other types of cigars are the togie or stogy, which are acheap type of cigar.

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RING GAUGE (DIAMETER)

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O

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1.PAREJOThe most common shape is the parejo, sometimesreferred to as simply "coronas", which have traditionally

been the benchmark against which all other cigarformats are measured. They have a cylindrical body,straight sides, one end open, and a round tobacco-leaf"cap" on the other end which must be sliced off, have aV-shaped notch made in it with a special cutter, orpunched through before smoking

Parejos are designated by the following terms-

1.Coronas2.Panatelas (longer & generally thinner than coronas)

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2 FIGURADO

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2.FIGURADO

Irregularly shaped cigars are known as figurados andare sometimes considered of higher quality becausethey are more difficult to make.

Historically, especially during the 19th century, figuradoswere the most popular shapes; however, by the 1930s

they had fallen out of fashion and all but disappeared.They have, however, recently received a smallresurgence(rising again) in popularity, and there arecurrently many brands (manufacturers) that produce

figurados alongside the simpler parejos. The cubancigar brand cuabaonly has figuradosin their range.

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Figurados include the following:-

Torpedo Like a parejo except that the cap ispointed.

Pyramid Has a broad foot and evenly narrows

to a pointed cap.

Perfecto Narrow at both ends and bulged in themiddle.

Culebras Three long, pointed cigars

braided together.

*In practice, the terms Torpedo and Pyramid are often usedinterchangeably, even among very knowledgeable cigar smokers.

T i

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The typical Italian cigar, created in the early 19thcentury when Kentucky tobacco was hybridized with

local varieties and used to create a long, tough, slimcigar thicker in the middle and tapered* at the ends, witha very strong aroma. It is also known as a cheroot ,which is the largest selling cigar shape in the UnitedStates.

shaped like a parejobut considered a figuradobecauseof its enormous size and occasional closed foot akin(related, similar) to a perfecto.

Tuscanian

Presidente/Diadema

*Tapered (cause to) diminish in thickness towards one end / become narrower

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CIGAR TYPES

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CIGAR TYPES

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CIGAR TYPES

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CIGAR FLAVOUR

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CIGAR FLAVOUR

Each brand and type of cigar tastes different. While the

wrapper does not entirely determine the flavor of thecigar, darker wrappers tend to produce a sweetness,while lighter wrappers usually have a "drier" taste.Whether a cigar is mild, medium, or full bodied does not

correlate with quality. Different smokers will havedifferent preferences, some liking one good cigar betterthan another, others disagreeing. Some words used todescribe cigar flavor and texture include; spicy, peppery

(red or black), sweet, harsh, burnt, green, earthy,woodsy, cocoa, roasted, aged, nutty, creamy, cedar,oak, chewy, fruity, and leathery.

Cont

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Cigar smoke, which is rarely inhaled, tastes of tobaccowith nuances(feeling) of other tastes. Many different thingsaffect the scent of cigar smoke: tobacco type, quality of

the cigar, added flavors, age and humidity, productionmethod (handmade vs. machine-made) and more. Afine cigar can taste completely different from inhaledcigarette smoke. When smoke is inhaled, as is usualwith cigarettes, the tobacco flavor is less noticeablethan the sensation from the smoke.

CIGAR CUTS

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CIGAR CUTSAlthough some cigars are cut on both ends, ortwirled(spin,swing,twist) at both ends, the vast majority come with

one straight cut end and one end in a "cap". Most qualityhandmade cigars, regardless of shape, will have a cap which isone or more small pieces of a wrapper pasted on to one end ofthe cigar with either a natural tobacco paste or with a mixture

of flour and water. The cap end of a cigar must be cut off forthe cigar to be smoked properly. It is the rounded end withoutthe tobacco exposed, and this is the end one should alwayscut. If the cap is cut jaggedly(cut unevenly or irregularly) or without care,the end of the cigar will not burn evenly and smokeabletobacco will be lost. Some cigar manufacturers purposely placedifferent types of tobacco from one end to the other to give thecigar smokers a variety of tastes, body and strength from startto finish. Smoking a cigar from the wrong end may result in a

bad experience.

There are three basic types of cigar cutters:

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There are three basic types of cigar cutters:

Guillotine (straight cut)

Punch cutV-cut (a.k.a. notch cut, cat's eye, wedge cut, English cut)

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GUILLOTINE (STRAIGHT CUT)

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GUILLOTINE (STRAIGHT CUT)The straight cut is the mostcommon, and is generally used oncigars with a smaller ring gauge.this cut uses a quick straight cutcausing both ends of the cigar tobe exposed. The double bladeguillotine is preferred by many

smokers over the single blade,because it usually makes acleaner cut. Cigar scissors arealso used to make straight cuts.

However these are most practical,the least expensive and can beeasily and safely carried. Mostprefer this cut because the entirecap end is exposed allowing formaximum smoke to exit.

V-CUT OR WEDGE CUT

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V-CUT OR WEDGE CUTV-cutters look like guillotinecutters, but cut a wedge into

the cigar cap rather thancompletely removing it,creating a clean looking gash(cut).

Good V-cutters penetratedeeper into the filler thanstraight cutters, and somesmokers prefers them for

thicker gauge (thickness) cigars.However, cheap V-cutterscan result in sloppy cuts toodeep into the cigar, whichresult in an uneven burn.

HOLE PUNCH

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HOLE PUNCH

The hole punch is used to put a hole in the cap of thecigar, Instead of cutting it off.

If the hole is not large enough for the cigar, the draw ofsmoke through the cigar can be impeded (obstruct/ hinder).Also as the cigar is smoked, tar can accumulate nearthe hole which affect the taste as well as the draw.

3 basic types of hole-punches are-

Hole-punch

Bullet punch Havana punch Multi punch

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HOLE PUNCH

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SERVICE OF CIGAR

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SERVICE OF CIGAR

The cigar service is a trendy addition to the food and

beverage scene and profitable one too.Customers who enjoy high-priced cigars are tend toorder costly drinks.

These points to keep in mind when serving cigars-Cigars should be offered in their own boxes to allowthe customer to choose his own.

The type of cigar will be printed on the box. Thecustomer having chosen the cigar he wishes, the waiterhas to remove the band before lighting.

Contd.

A cigar cutter or piercer should be given If the cigar is

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A cigar cutter or piercer should be given. If the cigar isnot pre-cut, then a clean V-shaped cut with cigar cutteris recommended. This allows the cigar to draw easily.

Cigars should not be pierced as this allows aninadequate draught and leaves a bitter taste in themouth, due to accumulation of tarin the cut end.

The waiter should then offer a matchbox or lighter tothe guest. Cigars must be lit with safety matches or agas lighter and not petrol lighter whose fumes would

affect the taste of the cigar.

SERVICE OF CIGARETTES

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SERVICE OF CIGARETTES

Cigarettes should never be carried by hand to thecustomer but placed on a salver or plate.

The packet should be opened (pulling out a fewcigarettes partially)

The waiter should stand by with a match to light thecigarette.

It should be made sure that the ash trays is on thetable.

Ashtrays should never be allowed to collect too muchof ash. It is the waiters duty to exchange themfrequently for fresh ones.

STORAGE OF CIGARS

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STORAGE OF CIGARS

Cigars are affected by light, temperature, humidity andfriction. Cigars should never be exposed to UV light.This will bleach (discolouring, fading, pale) the cigar wrapper,makes it less elastic and more likely to tear or rip. UVlight also changes the molecular composition of the

wrapper leaf in a rolled cigar.

A fine cigar should be kept at between 15 and 18*C andbetween 55 and 60% relative humidity.

A cigar will pick any smell or moisture in the air, or dryup & smoke like tinder. The safest way to keep cigars incondition is to buy, and offer them for sale in humidors.

TUBE

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TUBE

A tube will hold 1 cigar. a

tube case with a good sealcan protect a cigar formany days or even weeks.They are made of materials

ranging from plastic toplatinum. Some even mayhave a humidificationdevice built in.

FINGER CASES

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FINGER CASES

Cases made fromeither leather, metal,

wood or plastic. Theywill have 2 4fingers for the cigars.These are made from

2 telescoping piecesthat slide with in eachother. Made as percigar length but oftenvary from 1 1.5inches in length.

HUMIDOR

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A humidor is a box with ahumidification device in it to store

pipe tobacco or cigars. It has ahygrometer in it to keep a track ofthe humidity levels. Comes invarious sizes( for personal use

and as well as for bulk use.)

TRAVEL HUMIDORS

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TRAVEL HUMIDORS

These are miniature boxeswith a humidification device

and can hold between 4 20 cigars.

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A i i i h l ll d b dl f d i d d f d

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A cigar is a tightly rolled bundle of dried and fermentedtobacco that is ignited so that its smoke may be drawninto the mouth. Cigar tobacco is grown in significantquantities in Brazil, Cameroon, Cuba, DominicanRepublic, Honduras, Indonesia, Mexico, Nicaragua,Philippines, and the Eastern United States

Many modern cigars, as a matter of prestige and quality,are still rolled by hand, most especially in CentralAmerica and Cuba as well as in chinchales found in

virtually every sizable city in the US. Boxes of hand-rolled cigars bear the phrase totalmente a mano(totallyby hand) or hecho a mano(made by hand).

MANUFACTURING

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Tobacco leaves are harvested and aged using a processthat combines use of heat and shade to reduce sugar and

water content without causing the large leaves to rot. Thisfirst part of the process, called curing, takes between 25and 45 days and varies substantially based upon climaticconditions as well as the construction of sheds or barns

used to store harvested tobacco. The curing process ismanipulated based upon the type of tobacco, and thedesired color of the leaf. The second part of the process,called fermentation, is carried out under conditions

designed to help the leaf die slowly. Temperature andhumidity are controlled to ensure that the leaf continues toferment, without rotting or disintegrating. This is where theflavor, burning, and aroma characteristics are primarily

brought out in the leaf.

Once the leaves have aged properly they are sorted for

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Once the leaves have aged properly, they are sorted foruse as filler or wrapper based upon their appearanceand overall quality. During this process, the leaves are

continually moistened and handled carefully to ensureeach leaf is best used according to its individualqualities. The leaf will continue to be baled, inspected,unbaled, reinspected, and baled again repeatedly as itcontinues its aging cycle. When the leaf has maturedaccording to the manufacturer's specifications, it will beused in the production of a cigar.

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Quality cigars are still hand-made. An experienced cigar-roller canproduce hundreds of very good, nearly identical, cigars per day.The rollers keep the tobacco moistespecially the wrapperand

use specially designed crescent-shaped knives, called chavetas,to form the filler and wrapper leaves quickly and accurately. Oncerolled, the cigars are stored in wooden forms as they dry, in whichtheir uncapped ends are cut to a uniform size. From this stage,

the cigar is a complete product that can be "laid down" and agedfor decades if kept as close to 21C (70F), and 70% relativehumidity, as the environment will allow. Once cigars have beenpurchased, proper storage is usually accomplished by keeping thecigars in a specialized wooden box, or humidor, where conditions

can be carefully controlled for long periods of time. Even if a cigarbecomes dry, it can be successfully re-humidified so long as it hasnot been handled carelessly and done so gradually. However, theloss of original tobacco oils will greatly affect the taste.

Some cigars especiall premi m brands se different

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Some cigars, especially premium brands, use differentvarieties of tobacco for the filler and the wrapper. "Longfiller cigars" are a far higher quality of cigar, using long

leaves throughout. These cigars also use a third varietyof tobacco leaf, called a "binder", between the filler andthe outer wrapper. This permits the makers to use moredelicate and attractive leaves as a wrapper. These high-quality cigars almost always blend varieties of tobacco.Even Cuban long-filler cigars will combine tobaccosfrom different parts of the island to incorporate several

different flavors.

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In low-grade and machine-made cigars, choppedtobacco leaves are used for the filler, and long leaves or

a type of "paper" made from tobacco pulp is used for thewrapper which binds the cigar together. This alters theburning characteristics of the cigar, causing hand-madecigars to be sought-after.

COMPOSITION

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COMPOSITION

Cigars are composed of three types of tobacco leaves,whose variations determine smoking and flavorcharacteristics:

1.WRAPPER

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A cigar's outermost leaves, or wrapper, come from the

widest part of the plant. The wrapper determines muchof the cigar's character and flavor, and as such its coloris often used to describe the cigar as a whole. Over 100wrapper shades are identified by manufacturers, but the

seven most common classifications are as follows, fromlightest to darkest:-

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TERM DESCRIPTION

Double Claro

very light, slightly greenish also called candela or jade);achieved by picking leaves before maturity and dryingquickly; the color coming from retained greenchlorophyll ; formerly popular, now rare.

Claro light tan or yellowish, indicative of shade grown tobacco

Colorado reddish-brown (also called rosado or Corojo)

Colorado Claromid brown; particularly associated with tobacco grownin Cuba

Colorado MaduroDark brown; associated with Honduran or Cuba growntobacco

Natural light brown to brown; generally sun grown

Maduro Dark brown to very dark brown

Oscuro(double

maduro)

Black; often oily in appearance; mainly grown in

cuba,brazil,mexico,USA

2.FILLERS

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The majority of a cigar is made up of fillers, wrapped-upbunches of leaves inside the wrapper. Fillers of various

strengths are usually blended to produce desired cigarflavors. In the cigar industry this is referred to as a "blend".Many cigar manufacturers pride themselves in constructingthe perfect blend(s) that will give the smoker the most

enjoyment. The more oils present in the tobacco leaf, thestronger (less dry) the filler. Types range from the minimallyflavored Volado taken from the bottom of the plant, throughthe light-flavored Seco (dry) taken from the middle of the

plant, to the strong Ligero from the upper leaves exposed tothe most sunlight. Fatter cigars of larger gauge hold morefiller, with greater potential to provide a full body andcomplex flavor. When used, Ligero is always folded into the

middle of the filler because it burns slowly.

Fill b ith l h t l fill h l

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Fillers can be either long or short; long filler uses wholeleaves and is of a better quality, while short filler, also called"mixed", uses chopped leaves, stems, and other bits.

Recently some manufacturers have created what they term"medium filler" cigars. They use larger pieces of leaf thanshort filler without stems, and are of better quality than shortfiller cigars. Short filler cigars are easy to identify when

smoked since they often burn hotter and tend to release bitsof leaf into the smoker's mouth. Long filled cigars of highquality should burn evenly and consistently. Also available isa filler called "sandwich" (sometimes "Cuban sandwich")

which is a cigar made by rolling short leaf inside long outerleaf. If a cigar is completely constructed (filler, binder andwrapper) of tobacco from only one country, it is referred to inthe cigar industry as a "puro" which in Spanish means

"pure".

3.BINDERS

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Binders are elastic leaves used to hold together thebunches of fillers. Essentially, binders are wrappers that

are rejected because of holes, blemishes, discoloration,or excess veins.

SMOKING

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To smoke a cigar, a smoker possibly cuts it, lights it,then puts the unlit end into the mouth and draws smoke

into the mouth. Some smokers inhale the smoke into thelungs, particularly with little cigars, but this is relativelyuncommon otherwise. A smoker may swirl the smokearound in the mouth before exhaling it, and may exhalepart of the smoke through the nose in order to smell thecigar better as well as to taste it.

Al h h i b h d i l d

CUTTING

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Although some cigars are cut on both ends, or twirled atboth ends, the vast majority come with one straight cut endand one end in a "cap". Most quality handmade cigars,regardless of shape, will have a cap which is one or moresmall pieces of a wrapper pasted on to one end of the cigarwith either a natural tobacco paste or with a mixture of flourand water. The cap end of a cigar must be cut off for the

cigar to be smoked properly. It is the rounded end withoutthe tobacco exposed, and this is the end one should alwayscut. If the cap is cut jaggedly or without care, the end of thecigar will not burn evenly and smokeable tobacco will be

lost. Some cigar manufacturers purposely place differenttypes of tobacco from one end to the other to give the cigarsmokers a variety of tastes, body and strength from start tofinish. Smoking a cigar from the wrong end may result in a

bad experience.

LIGHTING

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The "head" of the cigar is usually the end closest to thecigar band. The opposite end of the cigar is called the

"foot". The band identifies the type of the cigar and maybe removed or left on. The smoker cuts the cap from thehead of the cigar and ignites the foot of the cigar. The

smoker draws smoke from the head of the cigar with themouth and lips, usually not inhaling into the lungs.

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When lighting, the cigar should be rotated to achieve aneven burn and the air should be slowly drawn with

gentle puffs. Cigars can be lit with the use of butane-filled lighters. Butane is colorless, odorless and burnsclean with very little, if any, flavor. It is not recommendedto use fluid-filled lighters and paper matches since they

can influence the taste. Another option is woodenmatches. They aren't treated and soaked with sulfur andthus the smoke is not affected with chemicals.

Cigars packaged in metal tubes will typically include athin wrapping of cedar. This may be used to light thecigar, eliminating the problem of lighters or matchesaffecting the taste.

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GOOD LUCK