Growing tobacco involves agricultural steps, transforming a tiny seed into the cured leaf used in cigarettes. This process requires careful attention to environmental controls and cultivation techniques. Before starting, verify all applicable state and local regulations, particularly concerning taxation and sale, as these laws can be extensive and complex.
Starting Tobacco Seeds and Initial Planting
Tobacco seeds are exceptionally small and must be started indoors approximately six to eight weeks before the last expected frost date. The seeds should be sown on the surface of a fine, moist seed-starting mix and should not be covered, as they require light to germinate. Maintaining a consistent temperature between 70 to 80 degrees Fahrenheit is important, as lower temperatures will significantly delay germination, which typically occurs within seven to fourteen days.
Once seedlings develop their first true leaves, remove the plastic cover and place them under strong light, such as fluorescent grow lights, positioned a few inches above the plants. Before transplanting outdoors, the seedlings must be “hardened off” by gradually exposing them to increasing periods of direct sunlight and outdoor temperatures over several days. This acclimation prepares the plants for the outdoor environment.
Transplanting into the garden should only happen after all danger of frost has passed, ideally in the evening to reduce transplant shock and wilting. Tobacco thrives in full sun and prefers well-drained soil with a slightly acidic pH, similar to what is suitable for tomatoes and peppers. Seedlings are typically spaced about two feet apart in rows, and while they may wilt initially, consistent watering until they are established is necessary for strong root development.
Cultivating and Maintaining Healthy Growth
The successful development of large, high-quality leaves depends heavily on two horticultural practices: topping and suckering. Topping involves removing the plant’s terminal bud, or flower head, as soon as it appears. This redirects the plant’s energy and nutrients away from flower and seed production and into the remaining leaves, increasing their size, weight, and nicotine content while promoting uniform maturity.
Following topping, the plant will attempt to grow secondary shoots, known as “suckers,” from the leaf axils along the main stalk. These suckers compete with the main leaves for nutrients and must be removed regularly to maintain the redirection of energy toward leaf development. If suckers are allowed to grow, they will reduce the yield and quality of the final harvest.
Throughout the growth phase, the plants benefit from a low-chlorine fertilizer, with nitrogen in nitrate form, applied in several instances during the early to mid-growing season. Proper fertilization ensures the leaves maintain a healthy green color and develop to a sufficient size. Adequate pest and disease management is also necessary, requiring growers to monitor the susceptible plants closely.
Harvesting and Initial Preparation
Determining the correct time to harvest is indicated by a change in the leaf’s appearance, with mature leaves beginning to lighten from deep green to a yellowish-green and sometimes showing a slight curling at the tip. Tobacco leaves ripen sequentially, starting from the base of the plant and moving upward, which dictates the two main harvesting methods.
“Priming,” the most common method for cigarette tobacco, involves picking individual leaves as they reach maturity, starting with the lower leaves first. This process is repeated weekly, removing two or three leaves at a time over several weeks until the entire plant is harvested. Priming allows for a more uniform maturity across the total leaf yield.
Alternatively, “Stalk Cutting” involves harvesting the entire plant at once by cutting the stalk near the ground when the majority of the leaves are ripe. This method, often used for Burley and dark air-cured varieties, is less labor-intensive but results in less uniform leaf quality. After harvesting, the leaves are prepared for curing by being tied into small bundles or strung onto sticks.
Curing and Drying the Leaves
Curing is a transformative process that drastically reduces the leaf’s moisture content, from approximately 80% to 15-20%, and initiates biochemical changes that develop the desired flavor and aroma. The green color fades as chlorophyll breaks down, and starches convert into sugars, a change that must occur slowly; if the leaf dries too quickly while still green, it will be harsh and unsmokable.
“Flue Curing” is the primary method for producing Virginia tobacco, desired for cigarettes due to its high sugar content and bright golden-yellow color. This method uses a controlled heat source to channel heat through pipes into a sealed barn, raising the temperature gradually over four to five days without exposing the tobacco to smoke. The process starts with a low temperature of around 100°F for “yellowing,” then progresses up to 160°F to dry the leaf and stem.
“Air Curing,” commonly used for Burley tobacco, involves hanging the leaves in a well-ventilated barn for four to twelve weeks, allowing them to dry naturally with ambient temperature and humidity. The slow, natural drying process results in a leaf that is low in sugar and high in nicotine, producing a darker, more robust flavor profile. Maintaining proper ventilation is essential to prevent mold growth, especially in humid conditions.
“Sun Curing” relies on direct exposure to sunlight to dry the leaves, a method frequently used for Oriental tobaccos. The leaves are spread out or hung in the open field until they are brown and withered, a process that can take 15 to 20 days. Sun-cured tobacco is typically low in both sugar and nicotine but is prized for its fragrant, herbal qualities.
Processing the Cured Tobacco for Use
Once the tobacco is cured, it is often brittle and must be “conditioned” by re-introducing moisture to make the leaves pliable enough for handling and cutting. This is accomplished by placing the tobacco in a humid environment or using a water mist, aiming for a relative humidity of around 65-70%. Conditioning prevents the dried leaves from crumbling and prepares them for the final stages.
The next step is often “aging” or “fermentation,” which significantly improves the flavor and smoothness of the tobacco. This process involves stacking the conditioned leaves in large piles, where internal heat and moisture trigger enzymatic reactions. These reactions break down harsh compounds like ammonia and further convert starches. Aging continues for a few months to several years in cool, dry conditions, allowing slow oxidation to deepen the flavor profile and reduce harshness.
Finally, the whole, aged leaves must be cut into the fine strips required for rolling into cigarettes. This is achieved using a specialized shredding or cutting machine that produces a fine, uniform cut, often called a “shag” or “ribbon” cut. The processed tobacco is now ready to be used as a filler for hand-rolled or machine-made cigarettes.