Do It Yourself: Tobacco Production

Do you want to make your own cigar tobacco? Cigarworld highlights the key things you need to know.

Is Tobacco Cultivation Allowed in Germany?

The most important question in this context is whether growing tobacco in Germany is even allowed. Fortunately, the answer is yes.

The Tobacco Tax Act exempts "tobacco products made outside an authorized manufacturing facility from small-scale tobacco and not intended for trade or commercial use" from the tobacco tax. Thus, tobacco harvests may not be used commercially and are solely for personal use.

However, the number of plants should not exceed 100. This figure is generally cited as a guideline, as there are no specific legal parameters in Germany on when cultivation might be considered commercial. Typically, about twelve plants are sufficient to cover the needs of an enthusiast.

Purchasing Tobacco Seeds: Where Can I Buy Seeds?

Tobacco seeds can be easily and legally purchased online or, of course, at your local gardening store. Prices vary depending on the type of tobacco and availability, usually ranging from two to four euros for 500 seeds.

What Types of Tobacco Are Suitable for Home Growing?

Several varieties are suitable for cigar use. Here are a few options that can be cultivated successfully in home environments.

Sand Leaves of the Plant

The sand leaves of a plant are ideal for producing tobacco for personal use. These leaves are low in nicotine and rich in aromatic oils and resins. Sand leaves refer to the lower leaves of a plant that come into contact with sand during rain or wind.

Typically, the lowest leaves of a plant are used only as filler leaves. They are not suitable as wrapper leaves, as they do not meet the visual standards required. Sand leaves, however, offer high-quality aromatic compounds. For the passionate smoker, this provides a special advantage: smoking produces a mild but flavorful experience.

Adonis

Adonis is a tobacco variety known for its mild and spicy flavor. It has good leaf quality and is resistant to extreme weather and other adverse environmental factors. The Adonis plant thrives best in loose soil. It is optimal to sow after February and to keep the plants cool thereafter. Planting out is recommended after the Ice Saints in spring.

Adonis tobacco is suitable as a wrapper for cigars but can also be used as a component in pipe-cut mixtures.

Havanna Z992

Havanna Z992 is a Havana hybrid that, due to its cross with the Adonis plant, is very low in nicotine. As a variant of Cuban Criollo tobacco, this variety stands out for its high quality, attributed to its resilience against Central European environmental conditions. This type of tobacco is suitable for cigars but can also be used in mixtures for fine pipe cuts.

Havanna Dunkelrot

Havanna Dunkelrot is considered one of the highest-quality tobacco varieties worldwide. It is ideal for tobacco cultivation in Germany and other European countries, as it withstands local weather conditions. Like other Criollo varieties, Havanna Dunkelrot can be used as filler tobacco or binder tobacco.

Brazilian and Sumatran Tobaccos

Both Brazilian and Sumatran tobaccos are suitable for cultivation in Germany. They have a strong, mildly sweet flavor reminiscent of chocolate. An intense flavor does not necessarily mean a high nicotine content. On the contrary, Brazilian and Sumatran tobaccos offer the possibility of emphasizing flavor intensity.

A cigar made with Brazilian or Sumatran tobacco is enjoyable to smoke, as aromas of chocolate, apples, or fresh bread often come through.

Growing Tobacco in the Garden or on the Balcony

Both options are feasible. As a light-germinating plant, tobacco requires sunlight to grow. Place it in a warm, bright spot, though not in direct sunlight.

Tobacco plants do not have high soil requirements. They need a lot of water, but the soil should not become waterlogged. Growing tobacco in pots on a balcony is also possible. Mix potting soil with sand or garden soil.

Sowing Tobacco Seeds

Tobacco seeds are generally frost-sensitive. Therefore, sowing tobacco seeds in spring is recommended, ideally from April to June. You can start early cultivation in a greenhouse. Here’s a step-by-step guide to optimal seed sowing:

1. In March, begin pre-cultivating seedlings. A greenhouse is ideal, but a heated propagation box indoors can also work. The optimal temperature is between 15 and 20 degrees Celsius.
2. When sowing, do not cover the seeds with soil, as they need light to germinate.
3. To encourage germination, spray the seeds with water regularly.
4. After six to twelve days, initial signs of growth appear: the seeds begin to sprout. Once the seedlings reach one centimeter, transplant them individually into larger pots.
5. For good root development, use pots with a diameter of 12-15 cm. When the plants reach a height of five to six centimeters, they can be transplanted to their final location.

Planting Out the Tobacco Plant

Planting typically takes place from mid-May (after the Ice Saints) through June. Ensure that no ground frost is expected.

In the garden, plant tobacco with row spacing of forty centimeters and a spacing of sixty centimeters between plants. The location should not be in direct sunlight, as this can burn the tobacco leaves—something you might want to do yourself only after harvesting! Additionally, remember that tobacco plants can grow up to 1.8 meters tall. Thus, planting under a tree or near low buildings is not advisable.

For tobacco cultivation, plant it in pots around 40 cm in size, with a soil mixture of three parts compost and one part sand. During the growth period, follow these guidelines:

• Water regularly, ensuring that no waterlogging occurs.

• Trim the flowers in time, as the plant otherwise diverts energy away from leaf growth.

• Loosen the soil regularly to ensure good aeration.

• Top and sucker the plants as needed.

Topping involves removing the flower heads along with a few leaves beneath them to stimulate stronger leaf development. Just days after topping, the plant will produce side shoots at the upper leaf nodes called "suckers," which also need to be removed. In general, the more that is trimmed from the plant, the higher the quality of the tobacco—but this reduces the number of leaves.

Harvesting Tobacco Plants

Harvesting tobacco leaves can begin as early as the end of July or approximately sixty days after planting out.

Before harvesting, consider how the leaves will be used. Cigar tobacco is heavily topped, meaning flower heads are removed immediately after they bloom. The flower stems are removed about 10-15 cm below the lowest flower branch.

To ensure cigars have the characteristic alkaline smoke, the tobacco should ideally contain no sugar. Thus, filler and binder tobacco is harvested in a semi-ripe state when the leaves are still dark green and just beginning to lighten.

Cigar wrapper leaves need to be thin, elastic, and pliable and should be resistant to tearing. Suitable leaves are those that ripen mostly in the shade, such as sand leaves and some mid-section leaves. They mature quickly, so during the first half of the harvest period, regularly inspect the crop to harvest leaves for wrappers at the optimal pre-ripened stage.

The ripe leaves are harvested from the bottom up, about three to four leaves per plant. The harvest period typically lasts six to eight weeks. Finally, the tobacco is taken to a location where it can dry and eventually be processed.

Further Processing of the Tobacco Plant

To produce tobacco, the plant must undergo further processing. Depending on personal consumption, various steps are involved, and understanding different processing techniques is essential for making quality cigar, pipe, rolling, or cigarette tobacco.

Producing Tobacco for Cigars

For cigar tobacco production, consider the following steps:

1. Once the tobacco reaches the right height, it can be processed into the plant. Place the seeds in a tray and water them adequately.

2. After about six weeks, each plant can be tied to its own spot. It’s best to create an outdoor bed in a semi-shaded area, protecting the plants from sunlight, rain, or frost. Cover the bed with a cloth if necessary.

3. The leaves can be harvested four to six months later, ideally before the plant blooms. Start the harvest from the bottom up.

4. Afterward, thread the tobacco leaves onto strings and hang them up to dry. A thin thread that pierces the main stem of the leaf is recommended.

5. Hang the leaves in a shady, airy, and slightly humid location. Ensure that leaves do not touch each other.

6. Once the tobacco has its typical brown color, it can be placed in a fermentation box.

7. During fermentation, tobacco leaves in the same condition should be fermented together.

8. Badly damaged leaves need shorter fermentation, about three weeks in the box.

9. After fermentation, the tobacco is ready to be rolled into cigars.

Producing Tobacco for Pipe Tobacco

Making pipe tobacco requires special treatment, as described in these steps:

1. Pipe tobacco is typically cut very thick, allowing the aroma to develop optimally in the pipe.

2. Cutting is crucial for pipe tobacco production, with a width between 1.5 and 3.5 millimeters; 2.5 millimeters is the most common width.

3. Some pipe tobaccos are pressed into a "tobacco cake." This pressing process requires high heat and lasts at least 12 hours. The more compressed the cake, the richer the aroma.

4. Aromatic enhancement, or flavoring, is achieved by applying natural flavors using a flavor drum. Options include brandy, rum, or even whiskey.

Producing Tobacco for Rolling Tobacco

Compared to pipe tobacco, rolling tobacco has shorter fibers, with a cut width not exceeding 1.0 millimeter. The production follows these steps:

1. Pressure is critical in making rolling tobacco, with expansion being a key factor.

2. The best expansion is achieved by introducing a highly volatile substance into the tobacco cells and then removing it. A volatile substance is one that readily vaporizes or appears as gas at room temperature.

3. To release nitrogen, the tobacco is steamed and shock-frozen under high pressure. This process expands the cells.

4. Various methods can be used for expansion, including steaming followed by high heating or using organic solvents or liquid carbon dioxide.

5. After expansion, the tobacco has its typical color and a voluminous, coarse, crumbly texture. Only a small amount is needed to fill a filter tube.

Producing Tobacco for Fine-Cut Rolling Tobacco

For fine-cut rolling tobacco, the cut width is crucial, with these guidelines to follow:

1. The cut width is between 0.3 and 0.65 millimeters, giving this type the name "fine-cut tobacco."

2. Fine-cut tobacco is also used in pre-made cigarettes.

3. Blending is an important factor, with at least two options for enhancing aroma: the Dutch blend and the American blend.

See also: Drying Tobacco and Growing & Processing Tobacco.