Tobacco is not just tobacco
Humidity control is essential for all tobacco production, but the correct humidity level also depends on the end-product. Different tobacco products require specific, varied relative humidity (RH) levels to maintain their quality, flavor, and burn characteristics. Cigars require the highest, most controlled humidity, while pipe tobacco and cigarettes generally require lower levels.
Why do cigars require a higher humidity level than cigarettes?
Premium product
Cigars differ significantly from cigarettes as it is a premium product. Whereas cigarettes are made to be smoked fast, cigars are carefully crafted to be enjoyed slowly and to kept for a long time. This is the reason why cigars require a higher humidity level than cigarettes so as to preserve their flavour, oils and delicate structure.
Ideal humidity level for each part of the cigar production process
1: Curing
For the curing process, a humidity level between 70%–75% RH is recommended. This is a little bit higher than for cigarettes production which generally lies between 60-75.
2: Fermentation
After the curing process, the tobacco leaves need to be stored until further processing. A humidity level around 60-80 % is recommended for this stage. This is necessary for removing impurities (ammonia, tar, nicotine) and to break down starches, and enhance aroma.
3: Stripping
During the stripping part, a humidity level between 70-75% RH is recommended. This helps to make the tobacco leaves pliable and prevent them from drying out while the stems are removed.
4: Rolling
During the rolling process, a humidity level between 65-70% RH is recommended. This is a delicate process for cigar production and the humidity helps to keep the wrapper, binder, and filler leaves flexible and prevent tearing during the rolling process.
5: Aging
During the aging process, a relative humidity level between 62%–68% RH is recommended. The gaing process of a cigar can last between 1-7 years depending on the type and on the wrapper.
6: Storage
During the storage process, a humidity level between 65-70% RH is recommended. The storage conditions are extremely important in order to preserve the cigar’s, taste, aroma, and structural integrity before sale.
Which type of humidification system is most suitable for cigar production?
Steam humidification
Steam humidification has long been praised for its hygienic, precise, and efficient humidification control in cigar production. However, the high energy consumption, high investment costs, risks of over-humidification and difficult maintenance, it is no longer the favored choice by most tobacco manufacturers.
Adiabatic humidification
Adiabatic humidification is the best choice for humidification control of cigar production due to its high energy efficiency, reliability and low investment cost. However, many adiabatic humidification systems produce large droplets which may harm machinery or wet the tobacco.
Dry Fog humidification
Ikeuchi recommends Dry Fog humidification control in cigar production. Our AKIMist® Dry Fog humidifier is known for its tiny droplet size around 7.5 µm. The droplets are so small that they bounce back without bursting on any surfaces. In addition, AKIMist is extremely energy efficient with an energy-cost ratio up to 80% lower than steam. AKIMist also has the added advantage of dust suppression, which can be a serious issue in tobacco processing locations.
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