The Magic of Cigar Production: The Art of Fermentation and Aging in Crafting Ultra-Premium Gran Reserva XO Supreme Cigars
Updated: Oct 6
Careful attention to tobacco plants and fields, as well as precise timing of leaf harvesting at full maturity, shapes the final product.
Only Long-Filler Leaves
For ultra-premium cigars, only long-filler leaves are used. These leaves are essential for achieving the complex flavors and superior burning qualities associated with high-end cigars. Unlike short-filler leaves, which are often used in lower-quality cigars, long-filler leaves are selected for their consistent texture and rich flavor profile. They are rolled in their entirety, providing a more uniform burn and a more refined smoking experience.
Using long-filler leaves ensures that every puff delivers the intended flavor profile, making each cigar a sophisticated and pleasurable experience. This meticulous selection and rolling process is crucial for maintaining the high standards of premium cigar production.
We use tobacco from the Kelner and Reyes families, which is a definitive mark of quality.
Tobacco Fermentation
Fermentation plays a crucial role in tobacco production, especially for ultra-premium cigars. This process not only removes impurities from the leaves but also helps develop their color and aroma, enhancing the overall quality of the final product. Tobacco undergoes several stages of fermentation, each essential for achieving the perfect result.
Why Ferment Tobacco Leaves?
Tobacco fermentation begins immediately after the leaves are dried and can last from 30 to 90 days. This process requires precise control over temperature and humidity, as improper fermentation can spoil the tobacco. It’s important to note that fermentation can be seen as a multi-stage process, sometimes involving two, or in the case of Zaven by G.P.Grant cigars, three stages.
Delicate wrapper leaves, due to their thinness, typically undergo only one fermentation phase. During the first phase, impurities such as proteins and carbohydrates are removed, nicotine, tar, and acidity levels are reduced, which softens the leaves and improves their texture. The second fermentation phase further enhances the flavor and removes remaining impurities.
First Phase of Fermentation
Once drying is complete, the leaves are stacked in piles called “gavilas” and covered with fabric to improve air circulation. The residual moisture in the leaves and the pressure from stacking cause a natural rise in temperature, leading to the start of fermentation. This process is similar to composting fruits and vegetables: microorganisms begin to decompose, which initiates fermentation.
To ensure high-quality tobacco, the temperature inside the piles should not exceed 35°C. The process requires constant temperature monitoring, and once it reaches the desired level, the piles are disassembled and the leaves are rearranged to ensure even fermentation. Leaves from the center are moved to the top, and those from the top are moved to the bottom. This process continues until all leaves undergo uniform fermentation.
It’s important to note that not all leaves ferment equally. Leaves from the top of the plant, which are thicker and contain more oils, require longer fermentation. On average, the first phase of fermentation lasts about 30 days.
Fermentation of Ultra-Premium Tobacco
For ultra-premium tobacco, fermentation is carried out with stricter control over temperature and humidity and takes longer to achieve the perfect flavor and aroma. The process includes several key elements:
Temperature Control: The temperature is maintained between 45-60°C, but it may sometimes be lower for a slower and more thorough fermentation, which develops more complex flavor characteristics.
Multi-Stage Process: Unlike mass production, ultra-premium tobacco can undergo several fermentation stages, allowing for the development of deeper flavors.
Use of Smaller Piles: The piles of leaves, or pilones, are smaller in size for better control of temperature fluctuations, allowing for more even fermentation.
Second Phase of Fermentation
Before the second fermentation, leaves are sorted, and central veins are removed at processing centers called “despalillo.” The leaves are then rehydrated and stacked in large piles, known as “burros,” weighing up to 2000 kg. Piles that are too small can lead to mold formation, while those that are too large may not provide sufficient moisture for fermentation. This phase lasts up to 60 days, with regular temperature monitoring to ensure it does not exceed 42°C.
If the temperature becomes too high, the piles are disassembled to allow the leaves to cool, then re-stacked, with the leaves being rearranged for even fermentation. The process involves several people and can take up to 4 hours. The second phase of fermentation ends when the temperature stabilizes.
Aging of Ultra-Premium Tobacco
Ultra-premium cigar tobacco is aged much longer than regular tobacco, allowing it to develop its unique flavor characteristics:
Aging Duration: This can range from 3 to 5 years, and in the case of Zaven by G.P.Grant cigars, 12 years (Gran Reserva XO Supreme). This allows the tobacco to “stabilize” and acquire softness and rich aroma.
Special Aging Conditions: Tobacco may be aged in special wooden boxes or rooms with controlled temperature and humidity. Cedar boxes are often used to add woody notes to the tobacco.
Final Fermentation: In some cases, before rolling cigars, the tobacco undergoes additional fermentation for final flavor balancing.
Unique Methods for Elite Cigars by Zaven by G.P.Grant
Producers of ultra-premium cigars, such as those from Zaven by G.P.Grant, use unique fermentation and processing methods, such as:
Triple Fermentation: This method gives the tobacco incredible smoothness and softness.
Additional Processing: Includes unique methods, such as aging in special conditions, which is the company’s know-how and allows for the development of richer and more complex flavor nuances.
Completion of Fermentation
After the second fermentation, the leaves are sorted again, aired out, and packed in bags for further aging. Aging can last from 6 months to several years, depending on the type of leaves and their intended use. The most aromatic leaves are aged longer to develop their flavor.
Limited Editions
Our cigars are produced in strictly limited quantities, ensuring exclusivity and exceptional quality, as mass production does not allow for the meticulous execution of all the aforementioned steps.
Cigar Production: Conclusion
The fermentation and aging processes of ultra-premium tobacco make it truly unique. The leaves acquire multi-layered flavors of cocoa, coffee, spices, wood, and dried fruits, creating a complex and rich flavor profile that is unattainable in mass production. These labor-intensive processes and long aging make cigars made from such tobacco some of the most expensive in the world.
The G.P.Grant Gran Reserva XO Supreme cigar collection represents the culmination of a meticulous approach to proportions and special methods of growing, curing, and rolling premium tobacco. Every stage of our production process, from seed to finished product, is a true work of art.
At G.P.Grant, our strict cigar quality standards are matched only by the discerning taste of our clients. While G.P.Grant cigars have a traditional origin, our rigorous quality control procedures are an integral part of our production, ensuring consistent quality and reliability, and high standards of premium cigars that have become synonymous with the G.P.Grant brand.
