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The Winter Sweat

Alex_SvensonAlex_Svenson Posts: 1,224 ✭✭✭
Somone was asking about various Connecticut wrappers a few weeks ago. I just wrapped up an article on a process called winter sweat which many people may not be familiar with that is a bit interesting.

For years, I’ve wanted to write about an extremely secretive process solely used in aging the tobaccos selected for America’s best-selling brand, Macanudo. This proprietary process, known as “winter sweat,” is such a well-kept secret that not even I was granted access to learn about it. After repeated requests to reveal the inner workings of this amazing procedure, I finally received the go-ahead to finally write this article as I was graciously awarded a rare, behind the scenes look at the “winter sweat” process.

Aging and fermentation are the single most important processes when preparing premium tobacco for blending. During this time, tobacco blooms its character and unique qualities, the ones that lend to those tasty, unique, and smooth flavors prevalent in any premium cigar. Every manufacturer utilizes secret processes in blending, aging, and fermentation, which they guard carefully and in many cases it is these secrets that create a signature trait or flavor profile from brand to brand. Ever picked up a cigar you weren’t familiar with and thought, “This reminds me of an Cohiba or La Gloria Cubana ?” What you’re noticing are subtle, specific nuances imparted into the tobacco during the aging and fermentation processes. While Macanudo may not be what many would consider a “boutique brand,” they employ some of the most unique procedures when processing their tobacco to ensure an unmatched level of quality and consistency is maintained.

“Winter Sweat” is a process reserved only for the Connecticut-shade wrappers destined for use in Macanudo cigars. A time honored tradition since 1968, the tobaccos are harvested in Connecticut in the summer months and cured in their native climate before shipping to the Macanudo factory in Santiago, Dominican Republic. Once in the Dominican, the leaves will slowly ferment much like any other tobacco in Latin America over a period of 2 to 3 years. However, to allow the tobacco to age at both hot and cold temperatures, the tobacco is shipped to a facility in Hatfield, Massachusetts to take advantage of the naturally colder and drier climate. During this time, the temperatures in the warehouse drop below 40 degrees Fahrenheit, pausing fermentation, thus putting the tobacco into a dormant state. “The process stops the buildup of ammonia in the leaves during the winter and helps promote the release of ammonia during the other nine months of the year when it’s back in the Dominican,” says Jhonys Diaz, Vice President of Operations for the Scandinavian Tobacco Group. “It’s an extremely laborious and costly process to move the tobacco back and forth, but it’s worth it for a brand that’s so dear to our hearts. This time-honored tradition is over 40 years old and still considerable part of the reason why Macanudo is the most recognized and best-selling brand in the US market today,” he adds.

I travel all over the world studying tobacco and cigar making and I can say, without a doubt, that the “winter sweat” process is one of the most unique procedures I’ve ever come across and only a brand as big as Macanudo possesses the resources to execute such an intricate and costly procedure in the name of perfection. I suppose that’s why you haven’t seen any other cigar makers attempt to replicate the “winter sweat” process and perhaps why they were finally willing to share the specifics behind its inner workings. To properly ferment tobacco, temperature control remains incredibly important and for most, it’s dictated by the local climate where Mother Nature can hold factories and their tobacco inventories hostage at will. By using the “winter sweat” process, Macanudo has found a way to seemingly allow the climate to work for them in all cases rather than against them by making their tobacco mobile, moving it with the seasonal changes in the northern hemisphere.

In my frequent interactions with consumers, it always amazes me how so many of the most fascinating and interesting parts of cigar making never make it to the ears of the enthusiast who will ultimately be lighting the actual cigar. The truth is that the “winter sweat” process is only one of the many unique and often secretive procedures employed by Macanudo. To find out more information you’ve never thought you’d know about your favorite smokes, follow us at Cigar.com as we unveil why cigars are truly the ultimate, affordable luxury; crafted by hundreds of hands over several years before they find their way to your humidor and ultimately, your palate.

Comments

  • MarkerMarker Posts: 2,524
    That is just plain cool. I love the Macanudo maduro and really really love the 1997 maduro. Two of my top 10 easily. Glad to see they have not skimped on those things that make the cigar brand special.
  • The_KidThe_Kid Posts: 7,869 ✭✭✭
    Thank You for sharing this rare and hidden process. I appreciate all the information that the cigar.com company provides, whether it be in a blog, here in the forum or in your monthy magazines. You guys are truly a class act.
  • Alex_SvensonAlex_Svenson Posts: 1,224 ✭✭✭
    I'm not a huge macanudo fan (although I love the 97 maduro), but I must say after seeing it, I have tremendous respect for the process.
  • MarkerMarker Posts: 2,524
    Alex Svenson:
    I'm not a huge macanudo fan (although I love the 97 maduro), but I must say after seeing it, I have tremendous respect for the process.
    I hear the tinkle of a Macanudo 1997 deal... Not that you need it Alex. Some of us (read: me) might. There are very few cigars right now that I feel I need to have more of. The 1997 Maduro is one of those. I can smoke those all day. Marker.
  • RBeckomRBeckom Posts: 2,191 ✭✭✭
    I greatly appreciate this post. I began growing tobacco this spring so any information on the ageing and curing process is information I can use. Please keep the knowledge flowing as I'm sure there's others like me who will put it to good use.
  • laker1963laker1963 Posts: 5,046
    Great read Alex,thanks. I could read this kind of stuff all day long.
  • jj20030jj20030 Posts: 5,804 ✭✭✭✭✭
    ordered a box of macanudo 97 maddys around may 5 and have had 2-3 but the one tonight has been just awesome so far
  • MarkerMarker Posts: 2,524
    They are all awesome JJ. I only have one 1997 so I am dreading when it is gone.
  • Alex_SvensonAlex_Svenson Posts: 1,224 ✭✭✭
    Get the 97 while you can. My understanding is that the manufacturer will be sold out at the end of the month and they will officially be gone forever. I loaded up to hopefully get me into next year.
  • Alex_SvensonAlex_Svenson Posts: 1,224 ✭✭✭
    RBeckom:
    I greatly appreciate this post. I began growing tobacco this spring so any information on the ageing and curing process is information I can use. Please keep the knowledge flowing as I'm sure there's others like me who will put it to good use.
    In your neck of the woods, growing should be easy. Curing and fermenting are the hard parts. If you need help, feel free to hit me up.
  • beatnicbeatnic Posts: 4,133
    I learn more every night. Thank Alex.
  • The_KidThe_Kid Posts: 7,869 ✭✭✭
    Marker:
    Alex Svenson:
    I'm not a huge macanudo fan (although I love the 97 maduro), but I must say after seeing it, I have tremendous respect for the process.
    I hear the tinkle of a Macanudo 1997 deal... Not that you need it Alex. Some of us (read: me) might. There are very few cigars right now that I feel I need to have more of. The 1997 Maduro is one of those. I can smoke those all day. Marker.
    tinkle tinkle +1
  • denniskingdennisking Posts: 3,703 ✭✭✭
    thanks for taking the time to write up on something that we all can appreciate. I've never even smoked a Macanudo (i know, weird) but I have an appreciation for all the hard work they put forth to give a consistent product.
  • grannejagranneja Posts: 382
    Great writeup Alex. Ia always enjoy reading the info you provide and the insight given into this industry.
  • very cool!
  • LasabarLasabar Posts: 4,472 ✭✭✭
    Fantastic read!
  • JudoChinXJudoChinX Posts: 775
    Great article!
  • RBeckomRBeckom Posts: 2,191 ✭✭✭
    Alex Svenson:
    RBeckom:
    I greatly appreciate this post. I began growing tobacco this spring so any information on the ageing and curing process is information I can use. Please keep the knowledge flowing as I'm sure there's others like me who will put it to good use.
    In your neck of the woods, growing should be easy. Curing and fermenting are the hard parts. If you need help, feel free to hit me up.


    I'll definitely have questions after I make A few mistakes. Trial and error, I have found, is the best education. Thanks.
  • KriegKrieg Posts: 5,188 ✭✭✭
    Great article Alex, I remember hearing about some cigar company out there who transfers their tobacco crop to northern US to DR every year, didn't know it was Mac. You have a great knack for writing some damn good articles. Thanks for the post.

    "Long ashes my friends."

  • wwhwangwwhwang Posts: 2,878 ✭✭✭
    Thanks for the great read, Alex. I love learning more about cigar production (especially the blending and fermenting processes). I wonder how the winter sweating method would affect cigars from other manufacturers. Mmmm...
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