Tobacco, a plant with a rich history deeply intertwined with human culture, has a character as complex as its centuries-old legacy. The Incas, Aztecs, and Mayans had a special relationship with tobacco and smoking pipes. The Native Americans had a special relationship with tobacco, too. Tobacco even reached Europe and became a staple of enjoyment across the pond. From Europe, it spread to the corners of the world. Now, what do all these cultures have in common across the smokes of time? They were all curing tobacco before smoking it. Most of the ancient civilizations were using air-curing or sun-curing methods. Yet, people are always looking for new and innovative ways to cure tobacco and enjoy it even more.
Last night, I sat back, lit my pipe, and tried a new tobacco blend my tobacconist recommended. It was different, and this sparked a thinking journey… how did they cure this tobacco? It was unlike anything I’ve ever had! While my tobacconist will never reveal all his secrets, I have the power of the internet on my side!
What started as a relaxing smoke before bedtime turned into a journey of discovery into the deepest rabbit holes of the internet. I wanted to learn more about curing tobacco and how it impacts the flavor of my newfound delight.
Buckle up! Today, we’re going on a journey of discovery to learn more about tobacco curing methods and how they impact the flavor of our favorite pastime.
Tobacco Leaf: The Canvas of Flavor
Before we explore the art of tobacco curing, we must understand the raw material – the tobacco leaf. These leaves come from tobacco plants, primarily Nicotiana tabacum and Nicotiana rustica, cultivated by skilled tobacco farmers worldwide.
Tobacco, like wine grapes, is a sensitive crop. The soil, temperature, and curing process affect the taste. The soil and climate determine where particular tobacco varietals can be grown (in wine terms, terroir). The curing process affects the final color and flavor of the leaves.
Before we can even dream about packing our pipe with tobacco, it must be harvested. There are two main methods of tobacco harvesting: priming and stalk-cut harvesting. Priming involves removing the individual leaves from the plant as they mature. In contrast, stalk-cut harvesting involves cutting the entire plant at ground level. Once harvested, farmers must cure the tobacco to remove the moisture and change the color of the leaves.
The curing process can be anything from a few days to several weeks. There are four main methods of curing tobacco: air, sun, fire, and flue-curing. Air and sun curing are natural processes that allow Mother Nature to work magic.
Air curing is the most common method and involves hanging the tobacco leaves in a well-ventilated barn. In contrast, sun curing involves hanging the tobacco leaves in the sun to dry and cure. Fire curing involves smoking the tobacco leaves over a fire, and flue-curing involves heating the tobacco leaves with hot air. The different curing methods produce different flavors and aromas in the tobacco leaves.
The type of tobacco curing method used depends on the desired flavor and aroma. We will look at these processes in more detail in the sections below.
Tobacco Varietals: The flavor journey begins with the selection of tobacco varietals. Each varietal boasts a distinct aroma, nicotine content, and characteristics contributing to the final product’s flavor profile. Some well-known tobacco varietals include Virginia, Burley, and Oriental tobaccos.
Leaf Chemistry: Any green leaf will contain natural sugars, oils, and flavor compounds. A tobacco farmer will tease out the unique tastes and aromas they want to shine through during curing.
The Curing Methods: Creating a Palette of Flavor
Curing is the art and science of transforming raw tobacco leaves into smokable treasures. Each curing method will change the tobacco leaves into a distinct product. The result? We get the opportunity to explore various smoking experiences.
Air Curing Method
Air curing, one of the earliest tobacco curing methods, dates back to Native American practices. Initially, tobacco leaves were left to dry in heaps, but methods evolved, revealing that hanging the leaves was more effective.
Typically, air-cured tobacco involves stalk-cut harvesting (cutting the whole plant at ground level). Harvested leaves will hang in well-ventilated barns for up to twelve weeks. The process is considered complete when the leaf’s central rib is moisture-free, resulting in tan to brownish-red or deep-brown leaves. Humidity is carefully controlled to prevent the leaves from developing mold or rotting. Sometimes, fans are used to hurry the drying process. After curing, the leaves remain in the barns to absorb enough moisture from the air. Skipping this step results in brittle leaves that cannot be sold or used.
Air curing takes the longest, but it delivers a natural curing process. The leaves will have a low sugar content, a mellow flavor, and higher nicotine concentrations. Burley and cigar leaf are common air-cured tobacco types. Cigar leaf and dark Burley undergo an extra step called “bulking.” Leaves are sorted by thickness and weight and then piled into heavy bales to start a controlled fermentation process. It is like a compost heap. The heavy pile of leaves generates heat, which causes them to ferment. During this process, the chemical composition changes.
Air Cured Taste
The bulking process uses the tobacco leaf’s natural biodegradation in a controlled way. The final product is a leafe with a deeper and more fermented flavor. Tobacco farmers can also apply extra heat, leading to a dark brown color because the sugars caramelize. For example, Dark Burley will have a spicier and richer taste than White Burley because of the bulking process. I’ve heard people describe the flavor as wine-like with a hint of cloves. I did pick up a hint of cloves in my new tobacco…
Sun Curing
Sun-curing, although often conflated with air-curing, has distinct differences. Air-cured tobacco is typically hung in ventilated barns or shaded areas with precise humidity control. In contrast, sun-cured tobacco is laid out on racks and exposed directly to sunlight for several days. This rapid-drying method retains some natural sugars in the leaves, imparting a subtle sweetness to the blend.
Oriental tobacco is grown in sunny, arid regions like Asia and the Mediterranean. Here, sun curing results in tobacco leaves ranging from yellow to orange. There is a trade-off: lower nicotine levels and a high sugar content. During sun curing, the tobacco can lose a significant part of its weight, often up to 90%, due to moisture loss.
Oriental tobacco is gathered one leaf at a time (the priming process) and is suspended on strings for about five days to sun-dry. This quick drying process preserves some of the natural sugar in the leaves, akin to how flue-curing affects Virginia tobacco. Although sun-cured Oriental tobacco contains only about half the raw sugar found in Virginia tobacco, it still contributes a mild sweetness when smoked.
Sun Cured Taste
Sun-cured Oriental tobaccos offer a unique flavor profile characterized by herbal and spicy notes. These tobaccos have a sweet and sour quality with nutty undertones. You can expect a complex range of flavors, from hints of cashew to lemongrass and cardamom.
While not inherently strong, sun-cured Oriental tobaccos are valuable blending components, providing delicacy and complexity without increasing the blend’s strength. In English blends, Oriental tobacco is often combined with Virginia and Latakia tobaccos, with varying proportions. The interplay between these components’ diverse flavors, influenced by their curing methods and any added toppings or flavorings during manufacturing, can create intriguing blend variations.
Flue-Cured Tobacco: A Happy Mistake!
Flue curing employs a specialized barn and indirect heat. Instead of exposing the tobacco leaves to direct fire or smoke, the process involves circulating hot air, smoke, or steam through a pipe (flue) within the curing barn. The heat from this source rapidly dries the tobacco leaves, resulting in a bright yellow color.
The flue-curing method originated in the 19th century on a North Carolina farm. It happened when a worker tasked with watching over curing tobacco fell asleep, and the fires began to die down. The worker added charred logs (or possibly charcoal) to the fire to revive the flames. The sudden and intense drying heat successfully removed moisture from the tobacco. The leaves turned bright yellow without damage to the crop. A happy mistake, we’d say!
Today, the traditional flue-curing barns are seldom used. Some barns are preserved along the East Coast for historical purposes. Modern flue-curing barns use propane as a heat source and boast sophisticated technology. These barns can be computer-programmed to precisely control temperature and humidity according to the farmer’s requirements.
The flue-curing process immediately starts after the tobacco is harvested to minimize damage or spoilage. It comprises a three-step process involving a gradual increase in temperature within the barn. The temperature progressively rises from 100 to 175 degrees Fahrenheit (37.7 to 79.4ºC). Careful leaves monitoring is essential at each stage to prevent potential damage. The process lasts between four and six days. After the curing, the doors are opened to allow the leaves to regain moisture from the atmosphere.
Flue Cured Taste
Flue curing preserves more sugar than other curing methods, and you’ll get tobacco with a slightly aroma and flavor while the nicotine levels are lower. Virginia tobaccos are the primary varietals used for flue-curing. Manipulating the temperature and duration of exposure to flue-curing can produce various types of Virginia tobacco.
For instance, bright Virginia results from a higher initial curing temperature followed by rapid cooling. The duration and temperature of flue-curing influence the tobacco’s color, strength, and flavor profile. A yellower leaf tends to have more natural sugar and less nicotine. In contrast, darker leaves have lost some sugar but retain higher nicotine levels.
Fire Curing Process
The rapid advances in curing techniques in the American colonies helped to secure dire curing’s place in curing processes. The early tobacco farmers realized that fire helped to preserve the leaves by removing dampness. The leaves could finally survive the long journey back to Europe. They also discovered that the fire gave the leaves a unique taste and aroma to the tobacco. A whole new curing method and preference for fire-cured tobacco was born.
The fire-curing process resembles the act of grilling tobacco leaves. These leaves are subjected to a smoldering fire, creating a unique, smoky, and woody taste. Usually, fire-cured tobacco is hung in barns, similar to those employed in air curing. However, these barns are tightly sealed to ensure maximum exposure to smoke. The choice between stalk-cut harvesting or priming the leaves from the stalk depends on the grower’s preferences.
Hardwood fires burn at a steady or occasional low smolder, varying from three days to ten weeks. This duration depends on the type of tobacco being processed and the desired outcomes. A fire is ignited on the barn floor and then covered with sawdust, which ensures a consistent smoldering effect. This gradual and consistent approach to curing prevents the loss of the natural oils present in the tobacco. As a result, fire curing yields tobacco with low sugar content but high nicotine levels. When incorporated into any blend, it imparts a spicy element to the flavor profile.
The choice of wood used during the fire curing process significantly influences the tobacco flavor. Hardwoods like oak and mesquite fires often cure the leaves in Kentucky and Tennessee.
Fire Cured Taste
Because of its intensified strength and flavor, dark fire-cured tobacco is usually used sparingly in blends. A prime instance of fire-cured tobacco is Latakia, which experiences sun curing before undergoing additional curing through controlled fires using aromatic woods and fragrant herbs. This dual-stage process imparts Latakia the characteristic black hue and smoky, peppery taste. Although Latakia is notably potent, it’s frequently used in English and Balkan-style blends as a condiment.
How Curing Impacts Taste
Curing is akin to a symphony where tobacco leaves, time, and method play their part. During this transformation, physical and chemical changes occur within the leaves, impacting the final flavor. We’ve posted before on selecting the right tobacco for your pipe and a review about tobacco blends.
Let’s look at the impacts in more detail below.
Moisture Reduction: One of the primary effects of curing is reducing leaf moisture content. This process intensifies the concentration of flavor compounds, contributing to a more robust taste.
As tobacco leaves cure, the moisture content decreases, concentrating the flavor compounds within. This intensifies the taste, making it richer and more pronounced. When tobacco is too ‘wet,’ it can taste harsh and burn unevenly in your pipe.
Chemical Changes: As the leaves cure, the breakdown of chlorophyll, starches, and proteins takes place.
During curing, complex chemical reactions occur. Chlorophyll, responsible for the green color of the leaves, breaks down, revealing the true colors of the tobacco. Starches are converted into simpler sugars, contributing to the tobacco’s sweetness. Proteins are transformed and return to their more straightforward form as amino acids that add depth to the flavor.
Sugar Development: Different curing methods lead to variations in sugar content. Flue-cured tobacco, for example, retains more natural sugars, resulting in a sweeter taste. Air-cured tobacco has a milder sweetness due to reduced sugar levels.
Stop thinking of sugar as only a sweetener; it is a crucial aspect of flavor and a flavoring agent. In flue curing, the heat and controlled environment lock in the natural sugars, creating a sweet and zesty flavor. But, air curing reduces sugar content, resulting in a more subdued sweetness with nutty undertones.
Nicotine Transformation: The curing process can also influence the nicotine content.
Nicotine content plays a role in the smoking experience. Higher nicotine levels can deliver a more robust and stimulating smoke. Lower nicotine levels provide a milder experience. Blenders often consider nicotine content when crafting blends to cater to different preferences.
Distinct Aromas: Each curing method imparts distinctive aromas to the tobacco. Sun-cured tobaccos often develop spicy and herbal notes, while fire-cured tobaccos acquire smoky, woody characteristics.
Aroma is integral to tobacco appreciation and influences our sensory reaction to tobacco. It affects the overall sensory experience. Sun-cured Oriental tobaccos evoke a sense of exoticism with their spicy and herbal notes. Fire-cured tobaccos create a robust and cozy atmosphere with their smoky and woody aromas.
Condimental Tobacco: Some tobaccos are used primarily as condimental tobaccos to enhance flavor in blends.
Condimental tobaccos are the spice rack of the tobacco world. They add depth and complexity to blends, much like spices do in cooking. Perique’s intense fruity aroma is a prime example of condimental tobacco that elevates the flavor. Latakia adds smoky woodiness to blends.
The Final Act: Aging The Tobacco
Once the blend is crafted, aging is the final chapter in tobacco flavor development. The blend is ‘rested’ in containers, allowing the flavors to meld and mature. Over time, aging can mellow sharp notes, deepen complex flavors, and enhance the overall smoking quality.
Aging is like fine wine aging in oak barrels. It’s the final step that transforms a blend from good to exceptional. The flavors marry and evolve as the tobacco rests, creating a harmonious and refined smoking experience.
Conclusion
Tobacco curing is an art; each method represents a brushstroke on the flavor canvas. For the record, I phoned my tobacconist the following day. I begged him to reveal the secret behind my new favorite tobacco blend. No, he still won’t reveal the secret. Do I understand the impact of curing on the taste of tobacco better? Absolutely. Am I going to ask more questions in the future about my tobacco? You bet I will! Smoking tobacco is a continuous journey of discovery for me, and I hope you’ll also be as enthusiastic about this journey as I am.
But back to reality for a moment. Understanding how our favorite blends are cured deepens our understanding and appreciation for the craft. Curing tobacco is a crucial process the ancient civilizations understood. If not for them, we wouldn’t have anything delicious to enjoy in our pipes today. Luckily, technology evolved, happy mistakes were made, and new methods gave rise to new curing processes. As you’ve seen, the curing process produces distinct results, enabling pipe enthusiasts to explore blends that align with their preferences.
Whether you’re a cigar aficionado, pipe enthusiast, or simply curious about tobacco, the world of cured tobacco holds a treasure trove of tastes waiting to be discovered. So, light up, take a puff, and savor the complexity of tobacco flavor—a journey worth embarking upon. Happy Smoking!
