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7-THE FERMENTATION PROCESS

The dried tobacco leaves are then sent to the fermentation house. On arrival, each area of production and each variety of tobacco is kept separately. The leaves are sorted by typei.e. Ligero, Seco and Volado.The fermentation period will be different for each type of tobacco.

Ligero tobacco: the strongest in flavour and nicotine content = long fermentation

Seco tobacco: mild flavour = medium fermentation

Volado tobacco: light flavour tobacco = short fermentation


The three conditions necessary for the tobacco fermentation are time, humidity and temperature.

In order to start the fermentation, the dried tobacco leaves are rehumidified. The fermentation process will then start. The leaves are put in large square piles.


The temperature is allowed to reach 51-53 degrees cent. The temperature is monitored on a daily basis using a thermometer that is inserted at the center of the pile in a tube. When the temperature reaches 51-53 degrees cent. the pile is then broken down and reconstructed, the top of the pile going in at the bottom and the outsides going into the inside of the new pile. The temperature is then allowed to reach the 51-53 degree cent. mark again. The process is then repeated untill complete fermentation. The first time the pile is built, the temperature will rise to 51-53 degrees cent. within 8/10 days.


A long fermentation (Ligero tobacco) corrasponds to 4-6 pile changes over 6/7 months. A short fermentation (Volado tobacco) corrasponds to 3 pile changes over 2 months.


During the fermentation process, the nicotine becomes more ammoniated. It is to be noted that all along its life the tobacco will produce some ammmonia. The more humidity, the grater the ammonia.


The variety of tobacco will also influence the fermentation time. for example, the Pilato Cubano will need more time than the Olor Dominicano or the San Vincente varieties.


The ferentation process will inflence the ageing potential of the tobacco; the heavier the fermentation, the shorter the aging process.


The Cubans do not ferment the tobacco as much as Davidoff. Therefore the tobacco needs a longer ageing process. They use low piles and therefore achieve lower temperature. As a consequence, the tobacco is less fermented and will require a longer ageing.


The fermentation process of the wrapper is a very long process, taking up to 7 months and involving at leasr 10 pile movements.