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Consuming Whole Leaf Tobacco that has not been processed is not advisable and it is perhaps
even dangerous. In order for Whole Leaf Tobacco to become consumable, it must undergo
special processing. Below are listed various processes needed to produce the tobacco of your

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liking.
Nitrogenous compounds and alkaloids are chemicals naturally produced by the tobacco plant.
These chemicals make smoking raw tobacco very unpleasant. Nitrogenous compounds and
alkaloids produce a smoke with a disagreeable odor and with an unbearable harshness.
HOW TO CASE (HUMIDIFY) TOBACCO
TOASTING WHOLE LEAF TOBACCO
Nitrogenous compounds and alkaloids are chemicals naturally produced by the tobacco plant. These chemicals
make smoking raw tobacco very unpleasant. Nitrogenous compounds and alkaloids produce a smoke with a
disagreeable odor and with an unbearable harshness. A process, know as toasting, is by far the simplest and
easiest way to prepare a smooth and fragrant tobacco for cigarette smoking and pipe smoking tobaccos.
Toasting involves heating the tobacco. The heat rapidly breaks down and releases the unwanted nitrogenous
chemicals and alkaloids from the tobacco. By removing these chemicals, the tobacco is much more refined. The
true flavor and aroma of the tobacco can now be appreciated and the harshness is much less pronounced.
Toasting involves placing shredded tobacco on a cookie sheet or metal tray and then placing the cooking sheet or
tray into an oven at a certain temperature for a specified amount of time (25 minutes). The temperature may vary
according to the type of tobacco being toasted. Burley has a large quantity of nitrogenous chemicals and
alkaloids so it requires a higher temperature. On the other hand, Virginia Bright Leaf does not contain as much
and it can be toasted at lower temperatures. Here is a step by step procedure to toast your tobacco:
If the whole leaf tobacco is too dry and has a crispy texture, you will need to humidify it before you shred
the tobacco. Place the whole leaf tobacco into a plastic bag and then spray the tobacco with a light mist
while in the bag. Seal the bag and let the bag rest over night. Tobacco will slowly absorb the water and
become more pliable. Check the tobacco the next day. If it is still crispy then repeat misting with water and
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allow it to rest overnight. Hopefully, by the next morning you will have tobacco that is nice and pliable and
the leaf should not be crispy. The reason why the tobacco is humidified is because crispy tobacco will
crumble and turn into dust during handling and processing.
Remove the mid-rib stem from the tobacco leaf. This stem runs from the head to the foot of the tobacco
leaf. You may discard the stem.
Once you have removed the mid-rib stem, you can shred it the leaf. You can use a shredder such as the
M-10 we have for purchase. Please refer to the Accessories tab.
Once the tobacco has been shredded, you can spread the tobacco over a cookie sheet so that it forms a
layer no more than a half inch. Making the layer to thick will result in inconsistent toasting.
Note, the toasting temperatures must be accurate. Do not rely on the oven's temperature gauge because
they are not very accurate. We sell CDN oven thermometers that are very accurate and durable. The
probe that is placed in the oven is attached to a digital thermometer by a braided metal wire. They are
surprisingly inexpensive. Please refer to the Accessories tab.
Now you will need to dry the tobacco. Preheat an oven to 150 degrees Fahrenheit (F). Then place the
tray into the oven for one hour. Then remove the tray from the oven. At this point the tobacco should be
very dry.
Now preheat the oven to 265 degrees F (if you are toasting Virginia Bright Leaf) or 305 degrees F (if you
are toasting Tennessee Burley). Now place the tobacco tray into the oven for 25 minutes. You will notice
an odor. This is good because it means that the unwanted nitrogenous chemicals from the tobacco is
breaking down and being released. The toasting temperature depends on the type of tobacco. As stated
above Virginia Bright Leaf toasts at 265 degrees F, Tennessee Burley toasts at 305 degrees F. These
temperatures are the upper and lower limits. All other tobaccos toast within the range between 265
degrees F and 305 degrees F. You will have to experiment yourself to find the optimal toasting
temperatures, but in general, heating between 275 to 285 degrees F for 25 minutes would be sufficient for
most types of tobacco.
After 25 min, take the tray out of the oven and let it cool. You will notice that the tobacco may have
darkened a little, especially the Virginia Bright Leaf. This is a good indication that the tobacco was properly
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toasted. The tobacco at this point is very dry, so it needs to be humidified again. Spray the surface of the
tobacco layer with water while the tobacco is still in the tray. Then cautiously use a spoon to mix the
tobacco. Be careful while mixing because the tobacco is very brittle and will crunch into dust. Spray and
mix until the tobacco is no longer crunchy. If you think that you added too much water and it seems that the
tobacco is too moist, then let the tobacco air dry for a while. Too much moisture may cause mold to grow
on the tobacco.
That's all there is to it! If you have any questions regarding this procedure, please send us an email by
using the CONTACT US on the home page. Good Luck!
KILN FERMENTATION OF WHOLE LEAF TOBACCO
Kiln fermentation is a method used to accelerate the aging process. Whole leaf tobacco is placed in a kiln at a specific
temperature (125 degrees F ) and humidity (70-75% relative humidity) for a period of four weeks. During this time, the higher
temperature stimulates the activity of the natural occurring enzymes in the tobacco leaf . These enzymes decompose many of
the harsh elements found in the tobacco leaf. In essence, the fermentation process is a method used to accelerate Mother
Nature's aging process.
As the name implies, kiln fermentation requires the use of a kiln. For the average person, kiln is basically a wooden box with a
heating element and a source of humidity, i. e., a water-filled crock pot. The use of thermostats allows one to control the
temperature and humidity in the chamber.
HOW TO MAKE CAVENDISH TOBACCOS
Black Cavendish refers to a method of processing raw tobacco to produce a very dark, mild tasting, and bite-
free tobacco particularly suited for pipe smoking. There is some ambiguity in terminology as Black Cavendish not
only refers to a method of processing tobacco, but it is commonly used to name the tobacco procured by the
Cavendish method of processing. Thus, I will ascribe the word Black Cavendish to refer to the type of tobacco.
Making Black Cavendish is a process whereby water laden tobacco is exposed to a heat source over a period of
time. There are a few methods for making Black Cavendish with the steaming process being the most
common, especially for large scale commercial production. In this method, the tobacco is subjected to a steady
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flow of steam until the tobacco acquires a black color. I have devised a simple method that is well-suited for the
small scale enthusiast which I will share with you as follows:
SELECTION OF TOBACCO: To make black Cavendish, any type of
tobacco can be used. However, I prefer to use Maryland leaf for two reasons.
First, Maryland leaf is mild in flavor, and, second, it has the capability to absorb
flavorings better than most all other varieties. Burleys are also used to make Black
Cavendish as well since they possess the ability to absorb flavorings. As with other
tobaccos, the fun comes with experimenting.
DESTEMMING THE LEAF: Destemming requires the tobacco to be well-
cased. See above HOW TO CASE TOBACCO. Once the leaf is in case, carefully
start separating the large center mid-rib vein beginning with the head (tip) of the leaf
and working your way down to the foot of the leaf (the bottom point where the leaf
is attached to the stalk of the tobacco plants). Repeat the destemming the other half
of the leaf. You will now have two long strips of tobacco per leaf.
PACKING THE CROCK POT: I use a crock pot as the source of heat.
Adding a little water provides the moisture needed to make the Black Cavendish. I
begin by stacking the strips of tobacco leaf. I then press down the stack of striped
leaves against a flat surface and roll the stack of leaves snugly starting from the leaf
head and working toward the foot. Then I place the roll of leaf strips into a crock
pot somewhat tightly.
STARTING TO CAVENDISH: Add enough water to the crock pot such
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that it fills to one centimeter deep. Turn on the crock pot. You will notice that the
water level will lower as the leaf strips begin to absorb it. You will have to add
water occasionally to prevent the strips from drying out especially those
leaves that make contact with the walls of the crock pot. You do not want to
have too much water in the crock pot or the natural tobacco components will leach
from the leaf and into the water. The leaf should be soggy at this point. You will begin to notice that the leaf will
begin to darken. It may take 24 hours more or less for the process to complete. You will know when it has
completed when the tobacco turns a very dark brown to black in color.
ADDING SWEETENERS AND FLAVORINGS: This step is optional.
Some people like to sweeten or flavor their tobacco. Once the process has
completed, you can now add any flavorings or sweeteners. For sweeteners, you can
dissolve sugar, honey, brown sugar or molasses in some water and pour it over the
tobacco. Similarly, for flavorings you can dissolve them in some water and add it to
the crock pot. Vanilla is a common flavoring. Amaretto, Rum and Anisette are very
popular and can be added straight to the crock pot. Let the crock pot cook for another hour or two so to
allow the sweeteners and flavorings to distribute throughout the leaf.
DRYING THE LEAF: Turn off the crock pot. When the contents have cooled
down, remove the leaf and unroll the leaf strips. Spread them over a cooking sheet
from the head to the foot. At this point you will notice that the leaf is very soggy and
easily tears. Let the leaf dry until crispy. Once the leaf has dried and the flavors
have locked in, you can mist them leaf and bring it back into case.
SHREDDING: To smoke the leaf in a pipe, you must have it cut and rubbed out.
Now that the leaf is well-cased, stack the leaves again and fold it once or twice.
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Press the stack of leaf with a press (some wood and C-clamps would do the job).
After an hour or two, slice the pressed leaf into long strips using a razor blade. Then
cut each strip further into fine strips. With a little rubbing out, you now have your
Black Cavendish ready to smoke.
SMOKING: This is the most important step. Pack a bowl and puff away!
HOW TO MAKE CHEWING TOBACCO
HOW TO FLAVOR YOUR TOBACCO
AGING WHOLE LEAF TOBACCO
The easiest way to prepare tobacco for smoking is to let the tobacco age. The tobacco leaf has natural enzymes
that breakdown nitrogenous chemicals and alkaloids. This is mother nature's way of preparing tobacco for
smoking or chewing. The tobacco is humidified and stored at room temperature for at least a year. Not only do
the enzymes breakdown and release the nitrogenous chemicals and alkaloids, but they also facilitate other
processes, such as converting starches into sugars thereby imparting a natural sweetness. As they leaf ages,
certain aromatic elements begin to buildup in the leaf and provide a fragrant aroma. Tobaccos such as Burleys do
not age well, but others, especially Virginias age spectacularly well. In fact, many Virginias are aged for three or
four years or even more to bring forth sweetness and aroma sought after by avid pipe smokers. Unfortunately,
this is not the most practical way to prepare your tobacco. Mostly, aging whole leaf tobacco is general geared
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for the advanced tobacconist. Resorting to toasting or kiln fermentation is probably your best bet.
A NOTE ON FLUE-CURED
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