Cigar
A cigar is a rolled bundle of dried and fermented tobacco leaves made to be smoked. Cigars are produced in a variety of sizes and shapes. Since the 20th century, almost all cigars are made of three distinct components: the filler, the binder leaf which holds the filler together, and a wrapper leaf, which is often the highest quality leaf used. Often there will be a cigar band printed with the cigar manufacturer's logo. Modern cigars can come with two or more bands, especially Cuban cigars, showing Limited Edition bands displaying the year of production.
Cigar tobacco is grown in significant quantities primarily in Brazil, Central America, and the islands of the Caribbean ; it is also produced in the Eastern United States and in the Mediterranean countries of Italy, Greece, Spain, and Turkey, and to a lesser degree in Indonesia and the Philippines of Southeast Asia.
Cigar smoking carries serious health risks, including increased risk of developing various types and subtypes of cancers, respiratory diseases, cardiovascular diseases, cerebrovascular diseases, periodontal diseases, teeth decay and loss, and malignant diseases. In the United States, the tobacco industry and cigar brands have aggressively targeted African Americans and Non-Hispanic Whites with customized advertising techniques and tobacco-related lifestyle magazines since the 1990s.
Etymology
The word cigar originally derives from the Mayan sikar. The Spanish word, "cigarro" spans the gap between the Mayan and modern use. The English word came into general use in 1730.History
Although the origins of cigar smoking are unknown, cigar smoking was first observed by European explorers when encountering the indigenous Taino people of Cuba in 1492. While tobacco was widely diffused among many of the Indigenous peoples of the islands of the Caribbean, it was completely unfamiliar to Europeans before the discovery of the New World in the 15th century. The Spanish historian, landowner, and Dominican friar Bartolomé de las Casas vividly described how the first scouts sent by Christopher Columbus into the interior of Cuba foundFollowing the arrival of Europeans with the first wave of European colonization, tobacco became one of the primary products fueling European colonialism, and also became a driving factor in the incorporation of African slave labor. The Spanish introduced tobacco to Europeans in about 1528, and by 1533, Diego Columbus mentioned a tobacco merchant of Lisbon in his will, showing how quickly the traffic had sprung up. The French, Spanish, and Portuguese initially referred to the plant as the "sacred herb" because of its alleged medicinal properties.
In time, Spanish and other European sailors adopted the practice of smoking rolls of leaves, as did the Spanish and Portuguese conquistadors. Smoking primitive cigars spread to Spain, Portugal, and eventually France, most probably through Jean Nicot, the French ambassador to Portugal, who gave his name to nicotine. Later, tobacco use spread to the Italian kingdoms, the Dutch Empire, and, after Sir Walter Raleigh's voyages to the Americas, to Great Britain. Tobacco smoking became familiar throughout Europe—in pipes in Britain—by the mid-16th century.
Spanish cultivation of tobacco began in earnest in 1531 on the islands of Hispaniola and Santo Domingo. In 1542, tobacco started to be grown commercially in North America, when Spaniards established the first cigar factory in Cuba. Tobacco was originally thought to have medicinal qualities, but some considered it evil. It was denounced by Philip II of Spain and James I of England.
Around 1592, the Spanish galleon San Clemente brought of tobacco seed to the Philippines over the Acapulco-Manila trade route. It was distributed among Roman Catholic missionaries, who found excellent climates and soils for growing high-quality tobacco there. The use of the cigar did not become popular until the mid 18th century, and although there are few drawings from this era, there are some reports.
It is believed that Israel Putnam brought back a cache of Havana cigars during the Seven Years' War, making cigar smoking popular in the US after the American Revolution. He also brought Cuban tobacco seeds, which he planted in the Hartford area of New England. This reportedly resulted in the development of the renowned shade-grown Connecticut wrapper.
Towards the end of the 18th century and in the 19th century, cigar smoking was common, while cigarettes were comparatively rare. Towards the end of the 19th century, Rudyard Kipling wrote his famous smoking poem, The Betrothed. The cigar business was an important industry and factories employed many people before mechanized manufacturing of cigars became practical. Cigar workers in both Cuba and the US were active in labor strikes and disputes from early in the 19th century, and the rise of modern labor unions can be traced to the CMIU and other cigar worker unions.
In 1869, Spanish cigar manufacturer Vicente Martinez Ybor moved his Principe de Gales operations from the cigar manufacturing center of Havana, Cuba to Key West, Florida to escape the turmoil of the Ten Years' War. Other manufacturers followed, and Key West became an important cigar manufacturing center. In 1885, Ybor moved again, buying land near the small city of Tampa, Florida and building the largest cigar factory in the world at the time in the new company town of Ybor City. Friendly rival and Flor de Sánchez y Haya owner Ignacio Haya built his factory nearby the same year, and many other cigar manufacturers followed, especially after an 1886 fire that gutted much of Key West. Thousands of Cuban and Spanish tabaqueros came to the area from Key West, Cuba and New York to produce hundreds of millions of cigars annually. Local output peaked in 1929, when workers in Ybor City and West Tampa rolled over 500 million "clear Havana" cigars, earning the town the nickname "Cigar Capital of the World". At its peak, there were 150 cigar factories in Ybor city, but by early in the next decade, nearly all of the factories had closed. Only one company still makes cigars in the Ybor City area, the J. C. Newman Cigar Company, which moved to Tampa from Ohio in 1954 and took over the previous Regensburg cigar factory. The company was continuing to utilize some antique, hand-operated ARENCO and American Machine and Foundry cigarmaking machines from the 1930's.
In New York, cigars were made by rollers working in their homes. It was reported that as of 1883, cigars were being manufactured in 127 apartment houses in New York, employing 1,962 families and 7,924 individuals. A state statute banning the practice, passed late that year at the urging of trade unions on the basis that the practice suppressed wages, was ruled unconstitutional less than four months later. The industry, which had relocated to Brooklyn and other places on Long Island while the law was in effect, then returned to New York.
In 1905, there were 80,000 cigar-making operations in the US, most of them small, family-operated shops where cigars were rolled and sold immediately. While most cigars are now made by machine, some, as a matter of prestige and quality, are rolled by hand—especially in Central America and Cuba, as well as in small chinchales in sizable cities in the US.
Manufacture
Tobacco leaves are harvested and aged using a curing process that combines heat and shade to reduce sugar and water content without causing the larger leaves to rot. This takes between 25 and 45 days, depending upon climatic conditions and the nature of sheds used to store harvested tobacco. Curing varies by type of tobacco and desired leaf color. A slow fermentation follows, where temperature and humidity are controlled to enhance flavor, aroma, and burning characteristics while forestalling rot or disintegration.The leaf will continue to be baled, inspected, un-baled, re-inspected, and baled again during the aging cycle. When it has matured to manufacturer's specifications it is sorted for appearance and overall quality, and used as filler or wrapper accordingly. During this process, leaves are continually moistened to prevent damage.
Quality cigars are still handmade. An experienced cigar-roller can produce hundreds of good, nearly identical cigars per day. The rollers keep the tobacco moist—especially the wrapper—and use specially designed crescent-shaped knives, called chavetas, to form the filler and wrapper leaves quickly and accurately. Once rolled, the cigars are stored in wooden forms as they dry, in which their uncapped ends are cut to a uniform size. From this stage, the cigar is a complete product that can be "laid down" and aged for decades if kept as close to 21 °C and 70% relative humidity as possible. Once purchased, proper storage is typically in a specialized cedar-lined wooden humidor.
File:CigarEyipantla 05.JPG|thumb|Vendor rolling cigars at the Eyipantla Falls in San Andrés Tuxtla, Mexico
Some cigars, especially premium brands, use different varieties of tobacco for the filler and the wrapper. Long filler cigars are a far higher quality of cigar, using long leaves throughout. These cigars also use a third variety of tobacco leaf, called a "binder", between the filler and the outer wrapper. This permits the makers to use more delicate and attractive leaves as a wrapper. These high-quality cigars almost always blend varieties of tobacco. Even Cuban long-filler cigars will combine tobaccos from different parts of the island to incorporate several different flavors.
In low-grade and machine-made cigars, chopped tobacco leaves are used for the filler, and long leaves or a type of "paper" made from reconstituted tobacco pulp is used for the wrapper. Chopped leaves and a pulp wrapper alter the flavor and burning characteristics of the result vis-a-vis handmade cigars.
Historically, a lector or reader was employed to entertain cigar factory workers. This practice became obsolete once audiobooks for portable music players became available, but it is still practiced in some Cuban factories.