Drying (40–60 days)In the Caribbean, tobacco drying is conducted with utmost care. Fresh leaves can contain up to 85% moisture, so the process is gradual. Leaves are paired, placed on poles, and hung in casa de tabaco — special drying houses designed for natural air circulation.
At the initial stage, leaves are placed in the lower sections, where humidity is higher, and then gradually moved upwards to drier, warmer zones. This ensures even dehydration without abrupt changes.
During drying, the leaves lose most of their moisture, change color from bright green to golden brown, and reach a state suitable for further processing.
Fermentation (1–2 years)After drying, leaves are grouped into manos — dense hand-tied bundles maintaining leaf orientation and structure. These are stacked into pilones, where the combination of weight, residual moisture, and heat initiates natural fermentation.
Inside the pilones, complex chemical transformations occur: sugar, ammonia, and some resins are reduced, acidity decreases, and a softer, balanced flavor profile develops. Temperature is strictly controlled, and the stacks are regularly rearranged to ensure even processing.
Fermentation can occur in multiple stages, depending on the leaf type and intended use.
SortingAfter fermentation, leaves are moistened to restore pliability and sorted by growth tier and characteristics:
- Ligero — top, densest leaves with high nicotine content and rich aroma
- Seco — middle leaves with a balance of flavor and strength
- Volado — lower leaves providing smoothness and even burning
Leaves that have not reached the desired stage undergo additional fermentation.
Second FermentationThe sorted leaves are re-stacked into pilones according to their quality and intended use. The process is strictly temperature-controlled: if overheating occurs, the pilones are disassembled and rebuilt, with layers rearranged for even processing.
Aging (6 months to 2 years)After fermentation, tobacco is aired, packaged, and sent for aging. During this period, tertiary aromas develop, the final flavor profile is established, and the character of the tobacco is solidified.
Optimal conditions are 16–18 °C with 65–72% humidity. With extended aging, the flavor becomes rounder, smoother, and deeper.
For Bonche production, only leaves aged at least two years are used, ensuring high flavor harmony and a noble structure.