Tuscan Cigars
The Tuscan cigar was born in 1818 thanks to Ferdinand III, Grand Duke of Tuscany, who founded a tobacco factory in Florence where fermented cigars were produced. One day, a heavy rainstorm soaked the tobacco leaves left to dry in the sun, and instead of discarding the product, it was decided to invest in a low-quality cigar for the people. The success was immediate, and production has continued to this day.
Today, the Toscano is produced by Manifatture Sigaro Toscano using natural fermented Kentucky tobacco. It is produced in factories located in Lucca, Tuscany, and Cava de' Tirreni, Campania, and can be made by hand or machine.
Sorting, Preparation, and Bathing
The tobacco used for making a Tuscan cigar is Kentucky tobacco. It represents about 1% of the world’s tobacco production, while in Italy, it is a notable agricultural excellence.
About 300 farmers in Italy work with this tobacco, making the country the top European producer of cigar tobacco.
Growing Kentucky tobacco presents several challenges. First, the high costs for the production process stages, then the highly skilled labor, specialized cultivation, and careful curing phase.
For example, one hectare of cultivation requires about 700 work hours. Labor costs exceed half of the final product's value.
Apart from soil cultivation and transportation, all other operations are done by hand, especially topping, harvesting, curing, and sorting. The workforce for harvesting and sorting is predominantly female: women are better at recognizing ripe leaves during harvest and sorting them based on quality during the sorting process.
(Freely adapted from: storienogastronomiche.it)
The first step in making the cigar is sorting. During this phase, the harvest is sorted, and unsuitable leaves are discarded. Wrapper leaves, grouped in bundles of fifty, are separated from those used for the filler. The leaves are then placed in special paper boxes and stored in thermally insulated rooms.
The second phase is preparation: the previously stored boxes, left isolated for several months, are unpacked, and the content is placed in specific metal cages.
The third phase is the bathing process. The metal cages containing the leaves are immersed in vats of warm demineralized water for less than thirty minutes. This process makes the tobacco elastic and resistant enough for processing. Additionally, the filler tobacco is prepared for fermentation.
De-stemming
During this phase, the wrapper tobacco bundles are quickly separated and shaken to loosen the leaves.
The arrangement of the lobes with the veins facing up is maintained until packaging, so the veins remain inside the wrapper.
The wet wrapper is highly perishable, and if it cannot be used quickly, it is stored in a refrigerator at a temperature between 5°C and 10°C.
Fermentation
The filler leaves are placed in metal containers to ferment. The fermentation process lasts 14-21 days and is determined by the high water content absorbed and retained by the tobacco during the demineralized water bath.
Drying, Beating, and Sieving the Filler
During fermentation, the tobacco is turned several times, and the masses are broken down for initial drying. These operations renew the supply of active oxygen and mix the filler, ensuring uniform fermentation.
At the end of the fermentation period, the stem is removed, a process called 'beating.'
Two types of beaten filler are used for the Tuscan cigar: a larger one (for hand-rolled cigars) and a smaller one (for machine-rolled cigars).
The filler for hand-rolled cigars is taken to manual rolling workshops, where cigar makers select the necessary amount for each individual cigar.
The filler will consist of both large and small beaten pieces to ensure uniform density throughout the cigar, and the arrangement of the various pieces will enhance airflow.
Manufacturing
The actual manufacturing of the Tuscan cigar is done by hand by cigar makers.
Their great skill lies in selecting the right amount of filler and rolling everything with perfect mastery to ensure optimal airflow.
The first step performed by the cigar maker is laying out the outer wrapper. In this phase, the cigar maker dips their fingers in a bowl containing corn glue and spreads it onto the wooden board. This way, half a Kentucky leaf, stretched and placed on the damp surface, adheres well. The outline of the cigar’s wrapper is then traced with the tip of a knife.
It's essential that the leaf veins run parallel to the rolling to prevent resistance and avoid the wrapper from opening during drying.
The second step is weighing and combing. The cigar makers take pieces of fermented tobacco, weigh them to ensure the correct amount, comb them, and arrange them to create a cigar of the right shape and consistency.
Finally, the third and last step is sealing. After forming the bundle, the cigar maker, keeping it tight, places it on the pre-shaped foot and lifts the lower edge of the wrapper. Then they begin wrapping the leaf diagonally and upwards, enclosing the filler. The irregular and asymmetrical ends are placed on a cutting tool to give the cigar its final shape.
Drying
Once the Tuscan cigar is rolled, it is inspected by a special commission, which transfers the suitable cigars to wooden frames with small mesh wire bottoms, while defective pieces are returned to the cigar makers for re-rolling.
Each frame holds 200 to 225 cigars, and they will remain there for 12 months, during which a final drying phase will reduce the excess water content, which is harmful for storage.
Maturation
The cigars are wrapped in a layer of cellophane for final maturation, which lasts about twelve months.
A further inspection then definitively selects the cigars fit for the market. At the end of the process, the cigar is ready to be purchased by connoisseurs who appreciate the craftsmanship and tradition behind its making.