BY NICHOLAS MELILLO

Ellington, CT 06.15.22 - When most people think of the state of Connecticut, they rarely think of it as producing some of the best and most respected cigar tobacco in the world. If you are a cigar smoker, you might have seen the word CT Shade or CT Broadleaf on cigar bands, boxes, or tobacco shops. Still, most don't realize the deep and rich history of the Connecticut River Valley that rivals that of Cuba. Before 1959, Cuba and Connecticut had a long history of trading cigar tobacco. Cigars produced in Cuba would use Connecticut seeds, and cigars manufactured in Connecticut would use Cuban filler tobaccos. To this day, Havana Seed is grown in the CT River Valley and Cubans use hybridized varieties of seed called US Type 61, aka CT Shade.

I grew up on Connecticut tobacco lore from my grandfathers, who smoked CT Valley cigars since I could remember. Their fathers smoked cigars manufactured in factories in New Haven, Bridgeport, and Hartford. CT lays claim to the oldest cigar factory in the New World, in Suffield. I did not fully realize the importance of Connecticut tobaccos in the world of cigars until I moved to Esteli, Nicaragua, in 2003. I was 24 years old and found myself among some of the greatest cigar makers in the world. Most were Cuban artisans who fled Cuba in the 1960s after Fidel Castro had nationalized the tobacco fields and factories.

I did not fully realize the importance of Connecticut tobaccos in the world of cigars until I moved to Esteli, Nicaragua, in 2003.

These Cuban master blenders departed Havana looking for similar climates and soils to grow dark air-cured tobaccos, aka cigar tobaccos. Nicaragua, also known as the land of lakes and volcanoes, became many Cuban cigar makers' new home. The fertile, rich volcanic valleys of Esteli and Jalapa mimic those of Vuelta Abajo and Pinar del Rio and yet are unique in their own right.

As I began my career running a cigar factory in Nicaragua, the Cubans would ask me, "De Donde Eres?" Where are you from? "Soy de Connecticut." I would reply, and their eyes would light up! I witnessed a tremendous amount of respect for this strange word “Connecticut” that was so familiar to me.

The origins of the word Connecticut derives from the Mohegan-Pequot word "Quinnehtukqut," meaning the "long tidal river." The CT River begins near the border of New Hampshire, flowing southward 406 miles through 4 states, and empties into the long island sound. 15,000 years ago, a large ice sheet covered most of this watershed terrain and eventually melted into a gigantic glacier finger lake known as Lake Hitchcock. After 3,000 years, Lake Hitchcock began to erode, causing it to drain into the Long Island sound and eventually transformed into the Connecticut River. In this lengthy process, the sandy loam of the lakebed settled on 30,000 acres north of Hartford, known today as the CT River Valley.

It is because of this River that Connecticut tobacco is so unique. Most cigar tobacco-growing regions are volcanic, but Connecticut's sandy loam soil created by the Laurentide Ice Sheet left very few rocks than in other areas of New England. On average, the CT River Valley has 33 inches of this topsoil.

As a result, perfect amounts of silt and clay permit excellent drainage and air circulation around the roots of the plants, causing them to run deep before hitting clay. Stable roots make for a strong and healthy plant and cause the tobacco to be naturally sweet and earthy, with flavors, unlike any other growing region in the world.

DISCOVERIES THIS PAST YEAR ... suggest that humans' tobacco use began 9,000 years earlier than previously thought.

It is unclear exactly how long indigenous communities had grown tobacco in Connecticut. Scholars have generally accepted that tobacco use dates back some 5,000 years ago, but discoveries this past year in the mudflats of the Great Salt Lake Desert in Utah suggest that humans' tobacco use began 9,000 years earlier than previously thought. Most indigenous communities used a strain of tobacco called Nicotiana Rustica, a much more potent plant than used today in cigars containing 3-4 times the amount of nicotine. This tobacco would cause the user to experience a psychoactive effect in which the shaman could communicate with the spirit world. As time went on and Europeans arrived in the Americas, less potent strains of Rustica and Nicotiana Tabacum began to grow and hybridize because they were more palatable and sweeter after fermentation.

In the early 1600s, a Dutch explorer named Adrian Block was the first European to travel up the Connecticut River and began trading tobacco with local tribes. Then, in 1640, the English arrived in Windsor, CT, and started growing tobacco in more significant quantities after recognizing the fertile locks of the river valley. Due to trade among sailors and early merchants, many settlers brought Cuban, West Indian, and Virginia seeds. These varieties started to hybridize with local varieties, known as Poke or Ottomauch, because they were not as strong or bitter, making them more favorable amongst colonists.

Over the next 100 plus years, the cash crop of tobacco began to grow significantly. Cigars were peddled via wagons and produced mainly on homesteads and farms throughout the valley. Then in 1810, the first factory was established in Suffield. By 1833, the Connecticut Broadleaf variety emerged and changed the world of cigars to this day. Broadleaf is known for its substantial-sized silky leaves, incredibly earthy, and naturally sweet flavor. It is also one of the most complex and challenging tobaccos to grow and ferment. Through my research, the origins of the broadleaf seed are not precisely clear. Many sources state a Maryland seed was brought to Connecticut and hybridized with local strains. However, different books say a Bahamian origin. Regardless, it is now considered one of the five main varieties from which all the other seed varieties come. The 5 are Mata Fina Brazil, Sumatra, San Andres Negro from Mexico, Habanesis or Cuba, and CT Broadleaf.

The growing season in the CT River Valley takes place between April and September. It then is hung in unique curing barns for another 2-3 months until the tobacco is packed in farmer's bales and shipped in refrigerated containers to the Caribbean and Central America. As weather challenges all farmers, Connecticut is no different. Connecticut's summer weather can bring hailstorms, micro tornadoes, insects, mold, and other diseases. If it passes through these obstacles, it faces even more challenges in curing barns and then years in fermentation.

Knowledge and know-how are crucial in every step of the journey, from seed to a cigar. However, what seems simple is much more complicated than it appears. Temperature and humidity play a pivotal role from the seed beds to the fields, fermentation, the production floor, and, finally, the humidor in tobacco shops. Any missteps in these areas can lead to the destruction of whole crops and the loss of massive investments in money and time.

Seedbeds / Greenhouses

The CT State Agricultural Experiment Station, established in 1875, was set up to "improve agricultural productivity and environmental quality, protect plants, and benefit Connecticut residents and the nation." One of the main goals of the experiment station has been to develop seeds that provide resistance to various diseases and insects in the fields. Over the past 100 years, farmers have generally accepted growing about five different Broadleaf seed varieties that give the best resistance.

Seedbeds generally begin in April when the winter starts to fade. Seeds take 55-65 days in greenhouses before being transplanted to the fields. Plants are typically trimmed with unique mowers in seedbeds for uniformity and concentrate growth on the root system to strengthen the plant before moving to fields. Developing a robust and healthy root system is crucial for a plant's survival.

Transplanting, Cultivating, and Topping

After seed beds, plants make their way to fields after land preparation. Broadleaf is well known by cigar makers for its large leaves and generally needs 42-inch rows with a width of 22-24 inches. It is essential to have proper spacing to prevent as much damage as possible. Many farmers in the CT River valley still possess special tractors with rotating wheels, and seating on the back helps plant seedlings efficiently—roughly 7,000 plants per acre.

At 55 days, depending on the variety, the plant's flower is removed from the fields. This process is known as "topping," and is crucial to concentrate energy into the leaves to promote flavor and thicker cell structure. Nutrients from the stalk focus on the leaves instead of producing a flower once removed. Topping contributes significantly to a broader, more oily tobacco which eventually adds to the flavor and body of the blend.

Harvesting

The harvesting of CT Broadleaf usually takes place 65 - 70 days after planting in the fields. Harvest depends on the ripeness of the leaves and takes a keen eye and years of knowledge to know the right time. Harvesting too early or too late could change the overall value and yield of the crop tremendously. Typically, tobacco is primed throughout the Caribbean and Central America, meaning 3-4 leaves are removed first from the bottom of the plant every six days until wholly harvested. Broadleaf is stalk-cut with a hatchet and left in the fields to wilt from 45minutes to 3hours depending on the climate. The broadleaf plant is shorter and stockier than most wrapper tobacco plants and usually yields 12 - 14 leaves.

Curing Barns

The tobacco is then transported from the fields via tractors to the infamous curing barns of the Connecticut River Valley. These barns are iconic for those who live near Bradley International Airport. Curing barns typically hold 5 - 8 acres of tobacco, hung by the stalk via wooden laths from top to bottom. During this period, small fires are lit on the floor of the barns, either via natural gas or charcoal, to help remove moisture. Curing tobacco in these great barns usually takes 60 + days, depending on the weather. The sides of the curing barns open and close, allowing airflow to help dry tobacco and control the internal climate. As a result, the leaves lose their green color and turn yellow and dark brown through this curing process. In addition, this process allows the slow oxidation and degradation of carotenoids, naturally occurring organic pigments in the leaf.

Curing is a critical and challenging process and greatly determines tobacco quality. You can have a fantastic crop in the fields and very quickly destroy a crop in the curing barns if you don't know what you are doing. The main goal is to remove the natural humidity within the leaf from the fields and to set the colors evenly, making it as uniform as possible. Any spots, tears, breaks, discoloration, or staining will automatically downgrade the quality classification. (In the handmade cigar industry, tobacco is classified as the wrapper (outside leaf), binder ( under the wrapper, used to hold together the filler tobacco), and filler tobacco which makes up the guts of the cigar.) Farmers usually know when tobacco is ready for packing when the central vein is at 18% moisture content and the colors are even.

Shipping to Central America and the Caribbean

After fully cured, tobacco is stripped in the barns and packed into 25 -30-pound farmer bundles. Leaves of inferior quality are typically removed and classified as stemming; tobacco commonly used for short-filler cigars. The rest of the plant is packed into 40 ft refrigerated containers holding 24,000 lbs. of tobacco. Since the bundles still contain 18 - 20 % moisture content, refrigerated containers are vital when shipping to the Caribbean or Central America to ensure tobacco doesn't mold or rot in transit. Suppose for any reason; that containers are delayed in transit and not climate controlled. In that case, it could result in destroying the whole lot.

Classification and Sorting

As the tobacco arrives in Central America and Caribbean factories, the first step is sorting the tobacco based on texture and thickness. Usually, the tobacco plant yields three classifications of thickness and strength. The bottom and thinnest leaves are known as Seco, the middle of the plant known as Viso, and the thickest, most robust leaves are known as Ligero. If workers do not sort leaves correctly, thinner Seco will cure much faster, while thicker Ligero leaves will not produce combustion. You will not have even fermentation and curing; as they pass to the production floor, it will be disastrous.

The second most crucial step is classifying tobacco by quality and size. In general terms, top-quality wrappers usually have 1, 2, 3, and sometimes four grades. One being the best. Leaves with one tear or blemish on 1/2 of the leaf classify as XL grades. Anything not passing as wrapper tobacco ranks as a binder, filler, and short filler. Binder is the leaf under the wrapper holding all the filler tobacco together. The filler tobacco, or tripa as it's known in Nicaragua, makes up the guts of the cigar. It is important to note that wrapper tobacco is the most expensive of the three parts of a cigar. The wrapper needs to be flawless in appearance, much thinner in texture, and elastic to roll.

Fermentation

Connecticut Broadleaf is one of the most challenging tobaccos to ferment. It has a large vein structure, retains more moisture, and the cellular walls of the leaf are generally thicker. Tobacco fermentation can be the best thought of as controlled composting, sometimes lasting 3years, depending on the variety. Tobacco is put into "hands" of 25-30 leaves known as gavillas and then meticulously stacked in 7,000 - 8,000-pound piles, known as pilones in Nicaragua. The pressure from the bulk and moisture from the leaf triggers the fermentation process. Thermometers are placed in the center of the piles and monitored daily. Temperatures cannot increase too quickly for a prolonged time because tobacco can be damaged very easily.

As the fermentation reaches certain temperatures, workers break down the piles of tobacco, and the gavillas are shaken and cooled. Then outer leaves of the pilone become the inside, and the inner gavillas become the outside. Then the fermentation begins again until temperatures sometimes of 125 degrees or more are reached. Finally, moisture is added at specific points when the tobacco has lost water. The humidity of the leaf and pressure of the pile are crucial in reaching desired temperatures to cure tobacco properly. Turning the piles continues for years until they are ready and approved to be packed in bales and passed to the production floor. Fermentation removes nitrogen compounds, reduces tar and nicotine levels, and makes tobacco sweeter and more aromatic, improving the flavor profile and overall combustion.

I often compare fermentation to my grandmother's pasta sauce, cooked at low heat for many hours. Low heat is essential to preserve flavor from evaporating into the elements when boiled or too hot. The same is valid with tobacco fermentation. It is possible to use 10,000 - 15,000 lbs. of tobacco and raise temperatures to ferment it much faster. But in the process, flavor and oils are sacrificed. Suppose you could imagine the financial investment and time needed for this process before you get a return. Unfortunately, many do not have the luxury of taking time, but this determines the overall quality and flavor of premium handmade cigars. I am fortunate to work with some of the best in the business and apply my grandmother's low and slow methods.

Tobacco bales

After 1 1/2 to 2 years of fermentation, tobacco is placed in large presses and packaged in bales. Depending on the country of origin, bales can range from 100 - to 300lbs. Companies with the resources take an extra step to preserve flavor and quality. They will stop fermentation a little early in the process, bale the tobacco, and age it for another 1 to sometimes three years before sending it to the production floor. Again, one must have the resources to undertake such a long aging process.

Production Salon

In Nicaragua, cigars are handmade in pairs - the bonchero or Buncher constructs the inside of the cigar, aka the filler or tripa. Then, the Rollera or Roller cuts and rolls the delicate and expensive wrapper leaf and forms the head of the cigar.

Blends are prepared beforehand and distributed via small bodegas on the factory floor. Each Bonchero and Rollera have unique cards with the blend and size they will produce daily. Yield is everything when making cigars; each pound of tobacco is recorded and compared to its daily production.

Bonchero or Buncher

The bonchero is in charge of the tripa or guts of the blend, meticulously placing each leaf in the proper position and then rolling the binder around the filler leaves. The bunches are then placed in unique wood or poly molds according to the size, pressed for 45-60min, and then rotated in the molds and pressed again. Cigars take their round shape after this process, making them ready for the roller to pass the wrapper leaf.

Before going to the roller, many factories' first quality control steps begin here. First, Revisors will review bonchero's technique to ensure they are not twisting the bunch and causing a tight draw. Revisors will also check if the blend is constructed correctly and if the tobaccos are at the proper humidity to use. Then, after cigars come out of the presses, they go to draw testing machines that measure the airflow through the bunch. If they do not pass, bunches must be re-made or chopped into picadura or short filler. Draw testing is a crucial step in the quality control process and the first net preventing inferior quality from reaching consumers' hands. It also stops the wrapper tobacco from being rolled, the most expensive leaf in the blend.

Rollera

Once the molds are pressed and approved for quality, they go to the roller: Depending on the type of wrapper, the roller will wet down the table and begin to stretch out half of a leaf horizontally.

A unique tool called la chaveta cuts the tobacco away from the central vein and the very outside of the leaf. Next, the center cut of the leaf, the filet, is rolled onto the bunch. Rollers do this skillfully using an order-less, tasteless vegetable glue to hold the wrapper, so it doesn't unravel. Next, the bunch is cut to the proper size using a special table guillotine. Finally, the cap or gorito forms using a unique tool called the casquillo, which cuts a round piece of the wrapper and places it at the cigar's head.

Quality Control

The quality control team then reviews finished cigars. First, revisors inspect each cigar by hand for soft spots, tightness, blemishes, and inconsistencies in color, diameter, length, and weight. Next, good quality cigars are approved and signed off using a special ticket on the production floor. This card has all the information about the cigar - blend, size, bonchero, rollera, and finally, the quality control signature. After this, the team weighs the wheels of 25 or 50 cigars to ensure each cigar uses the proper amount of materials. Wheels must come within an ounce of appropriate weight to pass quality control. If not, each cigar is reviewed and individually weighed until the problem is solved.

After cigars are checked in to inventory the next day, they go to the quality control room. Filtro 2. This room is entirely separate from the production floor, and the last net before cigars enter aging rooms. Here revisers review a selection of each wheel of cigars for any construction, draw, and wrapper problems. The cigars are then re-weighed once again to confirm they have used the proper materials.

Aging Rooms

Once quality control approves cigars, they enter the aging rooms. Of course, every company has its own rules when it comes to aging. First, the reader must understand that cigars from the production floor are generally much more humid than cigars in tobacconist humidors. Especially cigars that use darker or thicker wrapper leaves. A significant amount of moisture is absorbed by filler tobaccos when rolling the wrapper leaf. So, the purpose of most aging rooms is to remove this humidity naturally by placing the cigars in cooler climate-controlled rooms. Aging rooms typically have an air conditioning unit to help lower the moisture and naturally dry the cigars. Typically, in humidors in cigar shops, the climate is 70 degrees F and 70% humidity. In aging rooms in cigar factories, it generally is 60 -65 F and 60 - 65 % humidity. More sophisticated factories sometimes use meters that measure moisture content within the leaf, and cigars are not shipped until they reach between 12- 13% moisture content. Generally speaking, this can take anywhere from 30 - 90 days before cigars are packed in boxes and shipped.

Color Sorting and Packaging

Once cigars finish aging, they go to the color sorting tables before being banded and boxed. Unfortunately, it is impossible to color sort wrapper leaves before production. Therefore, the last step before packaging is sorting thousands of cigars to match color and uniformity. Hence, they look perfect inside boxes of 10, 20, or 25.

Conclusion

There are many more details to add to the growing, curing, fermenting, and rolling of CT Broadleaf tobacco. I have tried to explain it as simply as possible but simultaneously show the reader how much time, effort, and knowledge goes into handmade cigars. The Connecticut River Valley has profoundly impacted my life and career. I recently chose to build my new office for my company, Foundation Cigars, on a 100-acre tobacco farm in Ellington, CT. My mission over the next 5years is to share the history and importance of the CT River Valley in the world of cigars and continue to help farmers in the region. The Connecticut River valley is as vital as the Napa Valley or any other major growing area in the world. I hope you will help me with this effort to educate more people and preserve this national treasure.

Sincerely - Nicholas Melillo

www.foundationcigars.com

IG/Facebook/Twitter – Foundation Cigars

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