Hi -
I'm new to the forum and I'm glad I found this thread!
I read all the posts in this thread and I certainly can understand the confusion. There's a deliberate mystery involved with growing, curing and processing tobacco and it isn't necessary. Of course, there's a similar mystery in making beer and wine or growing fine bud.
I live in N. Central Texas, North of Dallas. Every year I grow from 250-300 tobacco plants. I harvest them, dry them and this year I built a kiln and fermented them fast for better smoke quicker then just air curing.
If you can grow tomatoes, you can grow tobacco. If ignorant peasants in the 16th Century could do it, you can do it too.
The seeds are planted indoors 6-7 weeks before your first average frost. They are transplanted to larger pots as they gain in size and finally planted out into the field.
During the growing season, they shoot up to 6-8 feet tall with leaves from 24-36 inches long (except some varieties like rustica which stays short and Turkish (oriental) that has many smaller leaves), then they flower. Typically, the flowers are topped off the plant. Then the plant puts out "suckers" (branches) which are removed to make the plant put more energy into making larger, thicker, heavier-textured leaves.
The harvest is different depending on the type of tobacco plant. Cigarette types (flue-cured and burley) are generally "primed", that is to say the leaves are removed from the bottom up as they yellow. Cigar, pipe, chew, etc. types are harvested by the whole stalk method.
Once the leaf/stalk is harvested, the leaves must "color cure", meaning change from green to yellow/brown, then they are dried crispy and then are ready for final curing.
Final curing can be as simple as packing in a box and waiting for up to a year or more - or as complex as building a kiln to maintain temperature and humidity to accellerate the fermentation process which makes the leaves smooth to smoke and not grassy or harsh tasting.
After this, there are a multitude of things you can do to it to make the leaves into the final product. It costs me about $3 a lbs to grow my own cig tobacco including processing and curing. It should be cheaper but I refuse to use any pesticides in my crop. 1 lbs of tobacco will make about 2-1/2 cartons of cigs. I also use no additives in my tobacco - I see no reason to put antifreeze in my smoke. (yes, the commercial cigs have that in them)
I hope that helps people here understand the basic overview of tobacco growing, harvesting, curing and processing.
I'll continue to watch this thread if anyone wants more info.
Bob
ps. don't get me started on complaining about the government's punitive taxation on cigs unless you have time for an ear full!......bk
pps. I tried to post a picture but it said I couldn't until I've posted 15 times here, so ask me lots of questions and then I'll post some....bk