tobacco industry

You cut your cigar, put a flame to the other end and experience a collection of tastes that is unique and fulfilling. But, have you ever thought about what makes it all possible? I'm not talking about the broad strokes. Sure, there's a guy who picks the leaves, another who roles them and so on. It doesn't take much to figure that out. Rather, I'm talking about the real details ... such as knowing to look for a leaf that may not be as long as the others, which can alter the flavor at the foot (or lead to intensity toward the end).

Blending and rolling is both art and science – we all know that – but the detail and care required likely exceeds your imagination. I've sat at a rolling table (briefly, on two occasions) and have a new appreciation for what goes into this task. When I sat in a conference room at the La Aurora factory in Santiago, Dominican Republic, though, I got a feel for the role of choice in constructing a cigar. And, to be honest, I was terrified. Making a great cigar doesn't start with the rollers: it begins with the arbiters of taste.

How do they do it? Here are five steps that may look easy on your screen, but they are terribly difficult in practice (especially with my palate).

The world has lost a great tobacco grower. Alejandro Robaina, a legend in Cuba and the rest of the world, died last weekend at the age of 91. His tobacco leaves wrapped some of the finest cigars seen in his lifetime. , starting on his family's fields when he was only 10 year old, having smoked his first cigar a year earlier. Since then, his handiwork was evident in brands such as the Cohiba Esplendidos and Hoyo de Monterrey Double Corona.

Robaina was something of a public face for the Cuban tobacco industry, traveling until age would no longer let him do so effectively. That's when smokers worldwide came to him, eager to see the environment – and the man –responsible for some of the most popular cigars on Earth, among others. His grandson, Hiroshi, now runs the show, having taken over as Robaina got older.

Even after Fidel Castro came to power, Robaina remained an independent tobacco grower, and he was named the best in the country by the Cuban government in the mid-1990s, receiving the award from Castro himself. In 1997, Habanos S.A. created the Vegas Robaina brand, the only one named for a Cuban tobacco grower. Yet, it smokes differently from most Cuban cigars, and doesn't appear to have much of Robaina's tobacco in it, according to James Suckling of Cigar Aficionado.

If you haven't lit up a La Aurora Serie 107 Anniversario yet, you've been missing something special. The cigar, which celebrates La Aurora's 107th year of operation in the Dominican Republic, actually caught me by surprise.

This cigar was not nearly as light as I expected it to be, bringing a lot of character and complexity. It was a bit spicy and stayed interesting from foot to ash. The medium-bodied cigar was great for me as late morning stick, but your specific timing may not be the same. The La Aurora 107 has a Sun Grown Ecuadorian wrapper and contains filler from Nicaragua and the Dominican Republic aged more than six years.

So, you could always get one of these cigars the ol' fashioned way ... you know, buy it. Or, you could wait until April 30, 2010, when 107 cigar retailers across the United States will be giving away 107 La Aurora 107 robustos.

Until last week, the closest I'd been to the cigar rolling process was to see on-site demonstrations at cigar shops. Even then, I understood that it wasn't easy, and that the speed with which the rollers worked was the result of years invested in their chosen career. My appreciation for this activity multiplied, however, when I stepped onto the rolling floor at Pepin Garcia's My Father Cigars factory in Esteli, Nicaragua and saw what felt like endless rows of cigar rollers, each taking a specific piece of the process: filler and binder, wrapper and cap. They worked quickly and quietly, each completing hundreds of cigars a day.

To see the operation at work was impressive, but to feel it was totally different. Even trying something as seemingly simple as wrapping and capping a cigar, I learned just how much craftsmanship goes into what we cut, light and smoke.

The leaf for the wrapper is delicate. Every cigar smoker knows this, but when it's waiting to be wound around the binder, the tobacco feels downright flimsy. I worried, appropriately, that the slightest stupid move would tear it and force me to start over. As I sat in the seat belonging to Jaime Garcia, Pepin's son, to roll a cigar, I was a little nervous. So many people around me were making it look so easy, and I knew that the reality, for me at least, would be far different.

When I asked Eddie Ortega what new cigars he has coming out this year, I wasn't surprised by his response. The man behind the 601 line doesn't have anything new hitting the shelves this year, and I'm pretty happy about that. So is he. Eddie – and Ron Melendi of De La Concha and Israel Markevitz of Uptown Cigar, with whom I spoke about this issue – believes that there isn't much need for new brands right now. Retailers have plenty of product in their stores, and consumers have no shortage of choices.

The cigar market is jammed right now. Every year, more than a handful of people get the brilliant idea that retailers need another line of cigars to pitch to cash-strapped consumers, and the established players tend to bring a steady stream of new concepts, exacerbating the situation. Of course, we need this: we can't let the cigar market go stale. But, we have to cope with a lot of bad ideas to get the good ones (I'm pretty excited about the Tatuaje vintage, for example).

The decision not to venture back into the market with a new line can be intimidating: it's a break from convention, which can always be unsettling. So, it's a bit gutsy not to follow the herd, but Eddie's air of confidence is hard to ignore ... as is the fact that he's right.

Through 2010, Eddie will focus on the cigars he already has on the market and ensure that as many people as possible realize that they should puff on a 601 at least occasionally (his personal preference is for the blue label). Even without a new product this year, Eddie has enough on his plate – and we have plenty to enjoy.

I met with Pete Johnson, the man behind the Tatuaje cigar line, after he and I met at Jose "Pepin" Garcia's cigar factory in Esteli, Nicaragua. His right arm, sleeved with ink, made Pete easy to pick out of a crowd. Since Tatuajes are among my favorites when I'm away from home, I was excited to learn what's on tap for 2010. Unsurprisingly, Pete has something in mind that's a bit different form the norm in the cigar industry.

Tobacco manufacturers strive for consistency above all else. They want the cigar you smoke next year to taste like the one you're smoking today. This is a sentiment I've heard from Pepin's operation and across the cigar industry. And, this makes sense. If you manufactured a high-quality product of any kind and sought repeat business, wouldn't you strive for consistency?

Sometimes, it really is possible to judge a book by its cover. From the moment you walk into a cigar shop, you take a quick look at its inventory and get a sense for the entire establishment. If the shelves are packed with low-end sticks, the discerning smoker will figure out pretty quickly that another tobacconist may be a better fit. And, there are the lounges you enter with everything from established favorites to rare and exciting cigars. Most of the time, you'll be able to get exactly what you want. In both cases, however, there is always the risk that you'll talk to someone who doesn't know what he's doing. Not every staff member is a great hire, and just because some great inventory is in the humidor, it doesn't mean the proprietor knows what he has.

Tobacconist University, founded by Jorge Armenteros, is trying to solve this problem. The organization, sponsored by Padron (a hell of an endorsement, frankly), provides a baseline education and testing structure to demonstrate to consumers that a retailer is knowledgeable. Simply, if you have a question about a cigar, the goal of the Tobacconist University certification program is to make you comfortable asking and confident in the answer.

The creator of Miami Cigar & Co. has decided that this coming Friday, June 12, 2009, is National Nestor Miranda Day. In exchange for claiming this particular day of the week, Miranda's Miami Cigar will be shipping free samples of the Nestor Miranda Special Selection 20 Aniversario Danno to 500 cigar retailers around the country. The only catch is that you have to buy a cigar from the retailer – any cigar, not even one from Miranda.

Each shop will be given 40 cigars, and 20 cigar retailers will be set up for much larger parties, which will be attended by key team members from Miami Cigar. Miranda will be at Sabor Havana in Doral Florida.

This promotion is the latest in a yearlong celebration of Miami Cigar's 20th anniversary.

Maybe, society has had enough. In Spokane, Washington, even non-smokers came to the defense of the cigar community when public golf courses tried to implement a ban. Other places are relying on creativity, such as tobacconist De La Concha's cigar dinners. In New Hampshire, the legislature is getting involved – a bill may legalize the sale of liquor in cigar bars.

In most places, it's tough to find a social setting where you can enjoy a cocktail and a cigar at the same time. The "live free or die" folks are looking to change that. If tobacconists are able to receive liquor licenses, the resulting store traffic could offset much of the damage being done by the financial crisis.

For Two Guys Smoke Shop in Salem, New Hampshire – where I used to go when I lived in northern Massachusetts – sales have fallen since the state banned smoking in restaurants two years ago, with particular effect in the winter. The ability to sell drinks would make the venue more enticing to customers, keep them in seats longer and likely result in an increase in sales.

There aren't many cigar venues left in New England or elsewhere in the country where you can smoke and drink at the same time. In Manhattan, we have a few spots, and Boston has Cigar Masters. Many cities have their hidden gems, but you have to find them. For the cigar smokers of New Hampshire, however, this could change. And, if you believe that Dixville Notch chooses the president every four years, expect to see similar laws pop up in other states.

Cut and light a double corona, and you're likely to draw comments about size, compensation and the like. So, imagine how the locals at your smoke shop would react to Jose Castelar's latest creation. He just set the world cigar rolling record (his fourth), doubling his last one. The result was a cigar 142 feet long.

The world record holder smoked his last record breaking cigar – 67 feet long – in 2005. At the time, he promised to continue breaking records ... and four years later, he's come through in style.

What's next? Castelar wants to roll a cigar the length of Malecon, Havana's six-mile seaside promenade.

The Cuban cigar roller, interestingly, limits himself to one cigar a day. What he does not say, however, is how long it is.

Cigar smoking is a lifestyle commitment ... and investment. Unless you're smoking low-end cigars, your daily spend is at least $5 and could reasonably reach $10. If you truly go upscale, you're looking at $20 a day or more, with boxes starting at $450. It becomes expensive quickly, and today, people are reconsidering how they use their "fun money." Unsurprisingly, pipes are gaining popularity as a cost-effective smoking alternative without forcing you into the nasty world of cigarettes.

At first, pipe smoking appears to be pricey. To enter the world of briar, you could lay out hundreds of dollars – even thousands. And, since you can't buy just one pipe, the cost multiplies. Once you get past the initial purchase, though, pipe smoking is quite affordable. Top pipe tobacco brands cost less than $15 a tin ... roughly the cost of a cigar.

Like cigars, pipes range from garbage to entry level to high-end. Generally, quality follows price. A $5 corn cob is what you would expect, and hand-crafted Dunhills – which can sell for more than $1,000 – may be a bit much for someone testing the waters.

All you cigar rookies, stand back! La Flor Dominicana Salamones is a big, hefty, full-bodied cigar that should be enjoyed on a full stomach in the evening while sitting in a comfortable chair with a rare bottle of port by your side. At more than $25 a stick, it's meant to be enjoyed, and the cigar delivers on even the highest of expectations.

This cigar by La Flor Dominicana is part of the recent wave of Salamones-style cigars that has come to market. This shape is quite difficult to create, especially with its large size. The perk, though, is that you get to watch an ash form that mirror's the cigar's original appearance, as a rich brown gives way to light gray.

The narrow foot results in a slight tightness of draw at first; the shape doesn't allow as much air to pass through. Over the first two or three minutes, you'll feel the Salamones open up, with greater volumes of smoke entering your mouth until you're enjoying the substantial mouthful's yielded by this delightful creation.

Nothing equates to having a cigar of this magnitude in your hand. It is enormous (roughly as big as a double corona), emits an amazing aroma and has a beautiful, oily wrapper. The ash holds easily for two inches before showing any signs of wanting to fall.

Cigar manufacturers are taking another look at the Salomon cigar style. It's a classic, according to Cigar Aficionado's Gregory Mottola, that many seem to have forgotten for a while. Rocky Patel, La Aurora and La Flor Dominicana are bringing back Salomon, and customers are voting for the size with their dollars. On that small island south of Florida, Habanos S.A. has added a new Salomon to its product line.

For those of you who are new to cigars, you probably haven't seen a Salomon. It's a fairly large cigar that's tapered at both ends, and it is often finished with a nipple foot. Don't confuse it with the smaller perfecto or larger diadema. Apparently, this isn't an easy size to produce, calling for a considerable amount of rolling skill and twice the time of a "normal" stick.

The SCHIP takes effect next week, and cigar smokers everywhere are dreading Wednesday. We've seen it coming, and I'm sure a few committed, deep-pocketed smokers have been stocking up to lock in discounts now. For the rest of us, though, there's no choice but to bite the bullet. And, in some places, that bullet is flying faster than in others.

Employees at the 16 Tocacco Depot stores, for example, have been rushing around to put new prices on various tobacco products, even though we still have nearly a week left. Fred Hoyland, who runs the show at that chain, says that some of the manufactures have raised their prices early – weeks in advance, even – in a play to beat the bargain hunters to the tax punch. Hoyland calls this "keep[ing] the market and inventory stable."

So, all your planning was probably for nothing. The house always wins ...

Habanos S.A., the official worldwide distributor of Cuban cigars, has developed a new way to thwart the efforts of the knockoff business. The company's introduced a new security seal that apparently has other safety features ... all of which are designed to prevent you from smoking a "Cohibo" while wearing your Folex and carrying Burbarry.

Specifically, there are two new elements on the Republica de Cuba warranty seal. One is a holographic label, which you'll find to the right of every warranty. The other is a barcode that will be on the left of the warranty. The seal is designed to fall apart if removed, making it impossible to reuse it on a box of fakes. Also, the barcode corresponds to a customized identification number stored in a database. One scan will show brand, size and market destination.

In the words of our esteemed former leader, "mission accomplished," right? Well, this all assumes that counterfeiters won't be able to build a better mousetrap.