Luxury tobacco from Lauenburg

Lauenburg

This year the destination for the summer holiday of Ellen and myself was Germany. Instead of staying in one location we opted to make a week-long trip from the North of Germany, Lübeck, to the Middle-East part; the Ahrtal. In between those two locations we resided in hotels and B&B’s. Of course I planned to visit several tobacco-shops and even a tobacco-factory: DTM in Lauenburg, situated on the northern bank of the river Elbe, east of Hamburg. Lauenburg is just a lovely old town with a picturesque historic centre alongside the Elbe. Small, enchanting streets up the hill lead to what is left of the once mighty Lauenburg castle. Also the view from there is stunning, you cannot only see the beautiful river Elbe and the old town, but also the flat marshland of Lower-Saxony. Lauenburg has one café/restaurant where you can smoke inside: the Alten Schifferhaus, where I left Ellen so I could visit DTM without her beautiful but prying eyes.

2015 Dan Pipe catalogue cover

2015 Dan Pipe catalogue cover

First of all, there are 2 separate business entities: Dan Pipe and Dan Tobacco Manufacturing (DTM). Dan Pipe is a retail and catalogue company. Dan Tobacco is a tobacco production facility. The history of Dan Pipe began in 1972 when, after a holiday in Denmark, teacher and enthusiastic pipe smoker Heiko Behrens decided to sell the creations of then unknown Danish pipe makers. In a small catalogue handmade pipes by Former, Emil Chonowitsch and Poul Hansen were presented together with factory pipes from Tabago, Torben Dansk, Danmore and other Danish producers. Soon also pipe tobacco was added to the catalogue, including Dan Pipe‘s first own-brand Torben DanskThe quality of the pipes and tobaccos from the Dan Pipe catalogue provided good word-of-mouth advertising amongst the German pipe-smokers so gradually the customer base grew.

Holger Frickert

Holger Frickert © Pipes & Tobacco Magazine

By 1976 the business was growing so rapidly that a new location was necessary. Behrens contracted craftsman (and aspiring young dentist) Holger Frickert to construct and design a showroom. Frickert was leading a class in art and design and that class rebuilt the shop in the form of a boat. It was an extraordinary design, with sails atop the room. Sadly I could not find any pictures of it.. Frickert’s passion for handicrafts, smoking and pipes led him to abandon dentistry and join Behrens’ business in 1978. He began repairing pipes as well as designing his own plus he became responsible for the catalogue presentation. The company was renamed for legal reasons in Danske Pibe“.

© Pipes & Tobacco Magazine

© Pipes & Tobacco Magazine

In 1985 Danske Pibe had grew so large that a much more spacious home had to be found. The Grashof”, a large farmhouse with thatched roof from the 18th century offered ideal conditions. There was space in abundance and on top of that the in 1987 lovingly restored old house, which also housed the store, had a special rustic charm. Over the years it became a magnetic pole in the northfor tobacco and pipe enthusiasts from all parts of Germany and the surrounding countries. Since the beginning of the 1980’s one of the specialities of the company were the house-brand tobaccos, which soon covered a wide range of flavours. But quality and delivery problems became a threat so decisive action was necessary. A new supplier who was able to cover the entire range of house-brand tobaccos was not in sight. Because of that the decision was made by Danske Pibe to establish their own tobacco factory. In 1991 a suitable building was found in Lauenburg and that was the beginning of subsidiary Dan Tobacco Manufacturing. Simultaneously the parent company returned to its old name Dan Pipe.

dan tobacco buildingThe DTM building is kind of special. It is an old former grain malting house, built of red brick into the steep slope of the Elbe river banks more than 100 years ago with a construction solid like an ancient castle. Enclosed by anywhere from several feet to several hundred feet of rock, the temperature and humidity in it varies no more than 2,5%. The ideal place for storing and producing pipe tobacco. The inevitable start-up problems were soon overcome and thanks to the creativity and experience of the employees of both companies they succeeded in a remarkably short time to generate a sizeable range of tobacco products. Those tobaccos were of such excellent quality that they gained a high international reputation. Thus exports to, for example, USA, Italy, Russia and Japan followed.

Pfeifen Timm

Pfeifen Timm

In 1994 Dan Pipe acquired 4 stores of the Pfeifen Timm chain in Hamburg’s city centre, a pipe-specialist well-known throughout Germany. Thus, the tobacco assortment now included many Timm house-brands. Even a fresh wind went through the cigar assortment and it was greatly increased. Sadly in November 2001 a fire laid the Grashof in ruins. Luckily in Lauenburg at DTM enough space was available, so it became the new home of Dan Pipe. The years during and after the financial crisis were difficult. The shops in Hamburg suffered losses and had to be closed. Dr. Heiko Behrens realised he needed help and so Maria Sousa became the other director. New sources of income had to be found in which the company succeed. Nowadays besides pipe-tobacco, high class water-pipe tobacco is made in Lauenburg.

Part of the Dan Pipe shop interior

Part of the Dan Pipe shop interior

I visited Dan Pipe / DTM several times now. But the first time (like so many things) was special. In 2012 I was busy with the quest for forum tobaccos. It was arranged that good friend and chauffeur Ed and myself would stay there for two days and visit the DTM factory. When we arrived we immediately noticed the sweet smell coming from the building. Someone was making a batch of aromatic tobacco for sure! Inside the Dan Pipe store shop assistant Ralph Kaschwich looked at us a bit questioning. “You come here for two days? Netherlands? Forum tobaccos? Let me make a phone call..” After a brief conversation things were cleared out and we were asked to wait for Andreas Mund, the master blender. That waiting certainly was not a punishment! The store has a beautiful interior from 1920 which is made from solid mahogany and comes from an old Hamburg pharmacy. It has many drawers and shelves where besides pipes about 140 DTM tobaccos are displayed in sample-jars. There also is a table with a bench where you can quietly sit, have a drink, take a piece of cake and (of course) smoke.

Andreas and me in the DTM warehouse

Andreas and me in the DTM warehouse

Soon Andreas greeted us. An ordinary looking man on first sight, you could take him for a construction worker if you saw him. Later it turned out that he actually had been a construction worker before he became involved in DTM. In 5 years he learned the tricks of the trade from former master blender Jürgen Westphal, who created almost all original DTM tobaccos and was going into retirement. The tour around the factory started at the top floor where the raw tobaccos are stored in lots of crates, boxes, bales and barrels. I do not know how many tons exactly but with a turnover of approximately 60.000 kg. per year you can imagine the scale of the place. DTM has to buy their leaf tobacco on the same terms as the big companies; by the container. So lots of tobacco have to be stored for quite a while before they are completely processed. Not bad, on the contrary,  it can slowly mature and improve its rich aromatic characteristics day by day. The tobaccos come from all over the world. Virginia from Brazil, India, the Philippines and Zambia, oriental tobaccos from Lebanon and Bulgaria, burley from Mozambique and Malawi, latakia from Cyprus, Kentucky from India and perique from the USA.

Andreas and a barrel of perique

Andreas and a barrel of perique

What surprised us was the transparency and openness business-wise in general. “I have so many tons of this and buy it for about that price so and so, etc.” The bottom line is that Andreas is also responsible for the purchase of raw tobaccos. For some of those he must wait nine months after ordering until they are finally delivered (eg. latakia), so he must carefully calculate whether his current stock is sufficient. It was remarkable that the dry, raw unprocessed tobacco indeed had no remarkable smell (long live casings). Well, except latakia and of course perique. Talking about that last one, DTM has a couple of barrels of the stuff, standing in a dark corner. Apparently perique and light are not a good combination. The smell of it is just… Whoaaa….Malevolent..

DTM_09In the next hall upstairs were the ready tobaccos waiting in large boxes to be further processed. Also here nothing was too crazy. Much was made open, it was grabbed, sniffed at. Delicious! I wished I had a couple bags of this tobacco I thought several times. I noticed that most employees smoked shag or cigarettes and no pipe. “Yes, we smoke pure Virginias here and no garbage made by Lucky Strike for example with 70% tobacco and 30% wood chips.” Andreas said. Incidentally he smokes a pipe but with the daily work cigarettes are just easier. Plus he uses cigarettes to try out new raw tobaccos. A trick he learned from Jürgen Westphal. If it does not taste in a cigarette, it certainly does not taste in a pipe.

Andreas and me before the flavour extracts

Andreas and me before the flavour extracts

On the lower floor in the building stood the old machinery which until recently was used for the production of tobaccos. Plus there were lots of shelves stacked with all kinds of aromatic extracts. “We are lucky.” Andreas said “The centre for flavour extracts is Hamburg, which is close to Lauenburg. There are many companies which make this stuff so it is very easy for us it acquire.” It was a very strange experience to smell some extracts. Sometimes it smelled so strong, so concentrated, that you could not figure out what exactly was inside a bottle. Also some flavours had several subcategories, for example Butter Vanilla, Crème Vanilla etc.

DTM_16When we walked around the corner to the next room we saw the mighty flake presses made by famous company Robert Legg from London. Stately red-black devices that looked like they were forged from ancient iron. 2 presses could be heated in order to make Virginia cavendish. However, this was not done because apparently it is cheaper to buy ready-made cavendish. The slabs of flake coming out of the machine are 9 kg. Nice to see that some of those slabs were for Hans Wiedemann’s HU Tobacco, who lets several of his offerings make by DTM. On another wall were so called postpresses. They are needed because the tobacco that comes from the big press has a tendency to expand again. The reason for this is that DTM wants to use Arabic gum (adhesive for the flakes) as little as possible.

Metal tobacco cylinder

Metal tobacco cylinder

Then we came in the big factory hall, the place of the large, new machine. An impressive sight, especially the big metal cylinder in which the raw tobacco is moistened and cased. Almost everything coming from the DTM factory is cased with honey. Large buckets of the naturally sweet stuff stood beside the machine on the sticky floor. The hall looked slightly blue of the vapours and smoke from the whole process. I will not describe in detail what happens because Ed made a short film about it.

Measuring the cut tobacco

Measuring the cut tobacco

But, in short: The tobacco is moistened/cased, then it gets compressed, cut, the moisture level gets corrected and eventually it all ends up in large boxes. However, the machine which had to cut the tobacco (made by German machine factory Winicker & Lieber who also make the machines for Mac Baren and Pöschl) did not (yet) function optimal. Therefore a little bit of the batch was cut and measured by hand so the machine could be recalibrated. This continued until the cut was right.

Packing department

Packing department

On to the all female packing department. I expected the work was done by machines but nothing could be further from the truth. Everything was done by hand! The tobacco weighing, putting it in tins/pouches, closing the tins/pouches, putting stickers on it.. I have so much respect for the women who do this work. When we were there they were mainly busy with pouches for Switzerland, a very large market for DTM. I had to laugh when Andreas remarked that those pouches contained a blend with 50% oriental tobaccos.Not good, not good..” He said, and pulled a dirty face. “Up to 30% in a blend, nothing more. But the customer is king.” Also the ladies were packing an aromatic blend of DTM. You could tell right away because the whole room smelled like candies were packed in stead of tobacco. The tour continued in the repair workshop. Pipes are being fixed here by boys who are still quite young. Some pipes shown to me belonged to a man who monthly needed new mouthpieces because he chewed them up.Pipes are to smoke, not to eat”, Andreas sighed with a smile. From the repair workshop we went to the tobacco warehouse of Dan Pipe. The place where everything in the catalogue (and more) is stored. Impressive to see all those tobaccos and pipe smoking paraphernalia.

Michael Apitz

Michael Apitz

Through the tobacco warehouse we came back in the store where Michael Apitz had joined Herr Kaschwich. He is responsible for creating many of the aromatic tobaccos of DTM. And is a walking encyclopaedia of everything that has to do with pipes and tobacco. Plus he is not afraid to share his knowledge and give his opinion, an intense man. I knew little of aromatic tobaccos so it was about time to speak to him. “Herr Apitz, may I ask something…” “No! First I have a question for you! How many tobaccos can one taste and judge on one day?” “Ehrrr, um… Three?” “No! Only one.” And a whole explanation followed. He showed and let us smell a lot of tobaccos together with an explanation of them. Very informative. With one of the first tobaccos which he took from the shelf he asked us what we smelled. As in, you never going to guess it. I smelled it.. And again.. Ehrr, aniseed? He looked at me with big eyes. Correct! *Phewww* Every time we were in the shop and there were no other customers he came up with another topic to talk about. Once again, very informative.

IMG_3357The last time I was there we spoke with each other non-stop for about 1.5 hour until I really had to get back to Ellen, who I left at the Alten Schifferhaus. Just before I went Herr Apitz asked me what I liked to smoke the most. “Well, a good Balkan I guess.” I answered. He then rushed to the tobacco warehouse and came back with a pouch of Bill Bailey’s Balkan Blend. “Here, this is for you, enjoy it!” Which for me characterizes Dan Pipe / DTM. Warm and passionate people with the typical “no-nonsense working hard and effective” German mentality.

Here are some DTM-made tobacco recommendations:
BiBo (Buddies): An ultimate aromatic statement created by Michael Apitz. The absolute pinnacle of sweetness. Forget the sweet American, Danish and Dutch blends, this one tops them all. It tastes and smells like Jaffa cakes, but then into the extreme. I once smoked this one in the evening in my living-room and asked Ellen what she thought. “Well, not bad” was the answer. Until she came downstairs the next morning.. “Whaaaat!? What is this odour? It smells like a friggin’ candy shop in here!” It took a week before we could not smell BiBo any more.. “I rather have you smoking latakia!” Ellen sneered in my direction.
Bill Bailey’s Balkan: A bit strange, Kentucky in a Balkan, but it works out well and results in a cool and satisfying smoke.
Midnight Ride: A rich, full flavoured classic English blend. If you want to know how Perique can work its magic in a latakia-mixture, try this one.
Old Ironsides: A latakia lovers dream. Dark and strong but also cool and creamy this flake makes you come back for more.
Skipper’s Flake: A no-nonsense straight Virginia flake. Pure unadulterated bright leaf heaven. ‘Nuff said.
Smooth latakia: One of the newer offerings, created by the wife of Andreas who also works at DTM. Black cavendish combined with latakia make this (like the name says) a smooth smoke. It reminds me a bit of McClelland’s Frog Morton.
Sweet Vanilla Honeydew: One of the few aromatic tobaccos I really like. Tastes like creamy vanilla and smells like those divine butter biscuits grandma used to bake. A real crowd pleaser.

Thanks go out to Paul and Ed for a lot of the pictures you see.

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Attractive Aromas

Me sniffing at raw tobacco leaf at the DTM factory

Me sniffing at raw tobacco leaf at the DTM factory

Tobacco leaf is the main source of flavour and aroma in any tobacco product (Duh!) But aside from latakia and perique (which are stinky enough from themselves) and orientals, raw leaf itself has little smell or taste. And by raw leaf I mean Virginias and burleys, they are almost always cased. For example, I’ve smelled pure and dry Virginias in the tobacco warehouse from the German DTM factory. It made me think of fish-food in stead of the hay-like aroma I am used to. Also tobacco crops vary from year to year, they are not consistent. So flavouring supplements are necessary to create both taste and aroma and help maintain a consistency in them. In the early days tobaccos had a subtle flavouring, but at the end of the 1960’s the high aromatics came into fashion. You know, the kind of blends that dissolve the glazing on your teeth and your girlfriend/wife love.  Anyway, additives to tobacco products can be classified in two categories: casings and top dressings (toppings).

No tongue bite please!

No tongue bite please!

Casings: Sometimes you read on labels of tins that a blend for example contains unflavoured Virginia and/or burley. Well, the truth is that very few tobaccos have no flavouring at all. Although a casing can be as simple as sugared water or honey. I know that DTM uses honey for the casing of many of their raw tobacco leaves, the factory floor is pretty sticky because of it. Casings are used at the early stages of tobacco processing to ease the negative qualities of a certain kind of leaf. Ehmm.. Some burleys can be somewhat sour and produce a more alkaline smoke, which can lead to the dreaded tongue bite. The use of a sweetener, a casing containing some sugar, can solve both problems. Some Virginias can be harsh, but also here, with the right casing that can be fixed. In general (of course their are exceptions) casings are not used to flavour the tobacco as much as to make it ready for other processing. Like you make a mild marinade for a piece of chicken to slightly give it a flavour, make it more tender and prepare it for cooking.

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Casing machine at DTM

The flavour of a casing should be compatible to the base tobacco that is used. For example, white burley has a certain kind of nuttiness and would match well with chocolate. Which is a commonly used casing for burley. The tobacco which has to cased is put into a machine that somewhat resembles a large clothes dryer with little sprayers on the inside. The casing is then heated and injected into the chamber. Through the use of tumbling, steaming and vacuum pressure the casing works its way into the leaf. Casings are often steamed into the leaf. The steam helps to open the pores and insert the added flavour into the tobacco. Because of this process, casings are usually water-based. After the casing of the tobacco it is dried. Often by putting the leaf on a conveyor which passes through a heated chamber. This reduces the overall moisture content of the tobacco to a level that is more manageable. This level generally is between 12% (pretty dry) and 22% (very moist). The ideal moisture for smoking depends on you, the smoker. But usually it is between 13% and 16%.

Rope tobacco

Rope tobacco

The following step will be determined by what the blend is supposed to be. If the intention of the final product is to be an unflavoured blend, for example a Virginia/perique or latakia blend, then the base tobacco is ready to use right after coming out of the heating chamber. The tobacco will be put in a container or something like that in which the finished blend, combined with the other components, is mixed and then is packaged. If the the final product is to be a plug, flake or rope the process starts with raw leaf that will be cased like I told above. After coming out of the casing machine the leaf immediately goes into the press. This because higher moisture is needed to get a good pressing. Or it goes through the drying procedure and is re-hydrated to the right level.

Thanks to top dressings the (in)famous Captain Black White is what it is..

Thanks to top dressings the (in)famous Captain Black White is what it is..

Top dressings (toppings): These are flavourings that most of the time are applied at the end of manufacturing process. That signature flavour, that particular tin aroma, that heavenly room note; all the responsibility of the top dressing. They are usually alcohol-based. When the water based casing is applied, the drying process will bring the tobacco back down to the correct humidity. But at the end of the process the blender wants to avoid having to use heat to re-dry the leaf a second time. So he uses an alcohol-based flavouring and allows the tobacco to rest for a couple of days. The alcohol will evaporate which leaves the concentrated flavour behind with little additional moisture.

Propylene glycol

Propylene glycol

Most casings and top dressings contain a “fixing agent” to assure that the flavourings will stick to the leaf and remain stable until used. In addition to fixing agents hygroscopic agents are used. Hygroscopic agents are chemicals used to control the moisture content of tobacco. They prevent the tobacco from becoming too dry in a dry climate or from picking up moisture in a humid area. The most widely used agents are sorbitol, propylene glycol and glycerine.

Andreas Mund and me before shelves full of concentrated flavours

Andreas Mund and me before shelves full of concentrated flavours

Concentrated flavourings are preferred by most tobacco blenders. This because the extract/concentrate can be manufactured much more uniformly and is less subject to changes while being stored than natural flavourings. When I visited the DTM factory I saw shelves and shelves full with all kinds of concentrated flavourings. According to master-blender Andreas Mund the city of Hamburg (pretty nearby the factory) is the centre of the world for concentrated flavourings. Lucky DTM! It was a strange experience when I opened up some of the flasks and bottles and sniffed the contents. You read something on the label like “chocolate” and when you smell it you absolutely don’t recognize it because it is THAT concentrated. So it won’t be a surprise that some blends use as little as 8 tablespoons of fluid per 100 pounds of tobacco.

Chocolate

Chocolate

Here are some of the most common flavourings:
Chocolate is manufactured as a natural product from the coco bean. It may be fortified with some cocoa which is synthetically produced.
Fruit flavours are obtainable in both natural and synthetic form. Natural fruit flavours are extracted from processed fruit.
Licorice comes from the licorice root and can be fortified with synthetic chemicals.
Menthol can also be made synthetically or it can be used in its natural state which is distilled from peppermint oil.
Rum used in tobacco is most of the time the Jamaican type. Jaaah man! It can also be synthesized.
Vanilla can be used in its natural form but for the most it is manufactured synthetically.
Wine flavours are as varied as the types of wine available: burgundy, sherry, madeira, etc.

Gawith & Hoggarth: Kendal's Banana Gold. One of the few blends anywhere with banana-aroma

Gawith & Hoggarth: Kendal’s Banana Gold. One of the few blends anywhere with banana-aroma

It is very difficult to create a good aromatic blend. You have to take in consideration the natural aroma of the leaf plus whatever the casing adds. Virginias often have a hay-like aroma and if that is not taken into account you could end up with something entirely different than you were hoping for. Also certain flavourings take advantage of other ones. A bit of vanilla boosts the taste of chocolate. Or flavourings have a tendency to overpower others, like coconut. And then there are flavourings that just don’t match with tobacco in general. For example, Paul has always looked for a blend with a nice banana-flavour and has not found one yet. Banana and tobacco.. Should work one would think. Well, I spoke with aromatic master-blender Michael Apitz from DTM and asked him why they did not have any blends with banana-flavour. He took me to the warehouse and showed some old tins with… Banana flavoured blends. “You know, there is a reason we don’t sell them any more and why they are collecting dust in the warehouse” he said. “They just don’t taste good and because of that people won’t buy them.” So it may take a whole lot of trying out before the aroma of a blend is acceptable.

And if you want to know why most aromatics don’t taste like they smell, have a look here: Who’s afraid of chemistry? (by Paul)

keep calmThese days every blender anywhere on the globe can make a high aromatic. But back in the days in the United Kingdom they had the “Tobacco Purity Law”. This law prohibited blenders from the use of large amounts of artificial flavourings and hygroscopic agents in the manufacture of tobacco products. In the early years of the Dunhill store Alfred Dunhill himself used to experiment at home with the creation of new blends. Regularly he got visits from police-officers who thought they smelled illegal things going on.. There was a list of additives that were approved and which had to be dissolved in alcohol or water. BUT they could only be applied at small percentages. For example, it was estimated that less than 0,5% of the weight of any given brand, manufactured in the United Kingdom, consisted of flavourings. This stood in contrast with some brands manufactured in the United States. There sauces constituted as much as 25% of the gross weight of the tobacco product. And in the case of Dutch tobaccos, this number was as high as 35%. So the blenders in the United Kingdom had to use the best quality tobaccos available, primarily the Virginia-type ones, orientals and condiment leaves like latakia and perique. And of course they had to have to skills to create outstanding mixtures. This with the help of all kinds of processing techniques such as stoving, toasting, panning, steaming and pressing. It wasn’t until the 1980’s that the Tobacco Purity Law was abolished by the Thatcher government so that American tobaccos could be sold in the United Kingdom.

Recommended aromatic blends are:
– Cornell & Diehl: Autumn Evening
– DTM: BiBo, Blue Note, Mediterraneo, Memories of Tuscany, Sweet Vanilla Honeydew
– HU Tobacco: Geniet Moment
– Lane Ltd.: 1-Q, Captain Black White
– Mac Baren: 7 Seas Regular Blend*
Neptune*
– Peterson: Sunset Breeze*
– Planta: Danish Black Vanilla*
– Stanwell: Melange*
– Sillem’s: Black
– Winslow: No. 1*, Harlekin*
– WO Larsen: Fine & Elegant*

* Available in The Netherlands

Candy Cavendish

Black cavendish tobacco

Black cavendish tobacco

If perique is the pepper of the tobacco world, if latakia is the salt, then cavendish is the sugar. Often it is used in aromatics and it is a good tobacco for beginning pipe smokers.

Almost all types of pipe tobacco in general belong to one of two groups: those used as the “base” of a mixture (like burley and Virginia) and those used for adding flavour, taste and aroma to a blend (such as latakia, perique and orientals. But cavendish can be used both as a base and as a flavouring agent.

Cavendish is a description of a type of pipe tobacco and a manner in which tobacco is cut.  It is not a type of tobacco plant. It rather is a process by which tobaccos are prepared. So there is no tobacco grown anywhere in the world that is known as a cavendish tobacco.

Sir Thomas Cavendish

Sir Thomas Cavendish

Now some history. In 1585 a visit to the English colony of Virginia was made by Admiral Sir Richard Grenville and Sir Thomas Cavendish at the request of Queen Elizabeth. The native people of the area presented tobacco to the colonists and Sir Thomas wished to bring it back to England for promotion and selling. On the return voyage he infused his personal supply with dark rum. Thus preventing it from drying out and to sweeten the smoke. He then rolled the leaves (common practice of the sailors back then) and bound them tightly together with sail canvas and twine. After a few weeks the tobacco was cut in little slices and smoked. Remarkably the flavour had improved, the tobacco was sweeter, more mellow and it demonstrated an aromatic fragrance. That all pleased Sir Thomas and others who tried it.

Steaming cavendish tobacco © Right Click Media, LLC

Steaming cavendish tobacco © Right Click Media, LLC

So cavendish tobacco simply is a product of “double” fermentation. This process uses (already one-time fermented) air-cured or flue-cured tobaccos like Virginia, burley, Maryland or any combination of these three types. These can be infused with substances that are high in sugar like: rum, maple, sugar, chocolate, licorice, honey, fruit, vanilla, bourbon and a few more. After the infusion the tobacco is compressed, steamed, heated, fermented and aged for a period of time. This results in a compressed “cake” of tobacco that is sliced and/or rubbed-out. For example, untreated, bright leaf (Virginia) tends to burn very hot and fast with a light, sharp flavour. The cavendish process makes this a more pleasant product. The tobacco is aged longer, burns slower, has a better taste and important, the ladies love the smell.

In the ol’ days the creation of cavendish tobacco varied from country to country and from manufacturer to manufacturer. Nowadays the whole process is more standardized and it doesn’t matter that much from which country cavendish comes. There are even manufacturers who don’t make their own cavendish any more because of the long process and just buy it ready-made. The countries which originally produced the most widely known cavendish tobaccos were: The United States, The United Kingdom, Denmark and last but not least The Netherlands. And they all had different production methods:

Cavendish manufactured in the United States
In order to get the tobacco to accept the required amount of casings it may be dipped (especially the burleys) into a casing sauce or heavily sprayed with flavouring sauces. The tobacco was then allowed to rest for a period of time. This way the tobacco and casings were wedded after which it may be subjected to pressure. It could take weeks or months until the blend had properly accepted the casing materials. The colour of the processed cavendish ranged from a light brown to black, depending on the leaf and casings used.

Cavendish Manufactured in the United Kingdom
The English manufactured their cavendish only with a heavier grade of Virginia. The tobacco was placed in molds and subjected to heavy pressure for three to four days. The pressure on the tobacco caused the natural oils to rise. Because of the heavy natural sugar content of the Virginia leaf the tobacco developed a sweet taste.

Sail: typical Dutch cavendish

Sail Regular: typical Dutch cavendish

Cavendish Manufactured in Denmark and The Netherlands
We Dutch and the Danes employed a slow manufacturing method. First steaming the tobacco to open the pores and then casing it very heavily. It was then placed in molds and subjected to pressure until a cake was formed which could be cut into bars an then into smaller pieces.

Black Cavendish
Then we also have the so called “black cavendish”. The two important steps employed in all manufacturing of black cavendish are:
1. The dipping of the tobacco into various casing, flavouring sauces (usually licorice) and
2. The steaming of the tobacco which turns it black.
For the rest the process is the same as with regular cavendish.

Black cavendish tobaccos can be manufactured from either Burley or Virginia leaf. Usually, the heavier and darker leaf grades are used. Since this tobacco is heavily impregnated with flavourings, the taste is naturally influenced by those.

The British also made black cavendish. The only difference is the restricted use of additives which made the taste more natural. So the usual method of processing this tobacco is to “sweat” and steam it. Which causes it to turn black. The tobacco is then placed in a mold and subjected to pressure for one to several days until a cake is formed. During this phase, additional steam may be applied.

As I said above cavendish also is a manner in which tobacco is cut. The term “cavendish cut” simply means a type of cut that is between a long or ribbon cut and a heavy fine cut.

Blending Pipe tobaccoMany smokers prefer to smoke straight cavendish. But it is often blended with other tobaccos such as burleys and Virginias. If you are making your own blend, start by mixing equal amounts of unflavoured cavendish and burley. This will give you some idea of the use of cavendish as a base. If you wish you can keep adding it until it makes up as much as 90% of the mixture. What you can also do is to take plain white burley. Then add for example about 25%  cavendish flavoured with honey (or another flavour) to the blend. This way you will get a mild smoke with very lit­tle aroma. When you use cavendish together with latakia and orientals (an English or Balkan mixture) about 15% is the max.

There are many, many, many blends that use cavendish. This are the most recommended ones:
– Amphora: Full Aroma*
– Borkum Riff: Cherry Cavendish*
– Cornell & Diehl: Autumn Evening
– DTM: BiBo, Blue Note, Memories of Tuscany
– Just For Him: Shortcut to Mushrooms
– HU Tobacco: Geniet Moment
– Lane Ltd.: Captain Black White, 1-Q
– Mac Baren: 7 Seas Regular Blend*, 7 Seas Royal Blend*
Neptune*
– Planta: Danish Black Vanilla Flake, Pergamon
– Poul Winslow: Harlekin*, No. 1*
– Sail: Regular*
– Samuel Gawith: Black Cherry, Celtic Talisman
– Sillem’s: Black
– Stanwell: Melange*
– Troost: Aromatic Cavendish*, Black Cavendish*, Special Cavendish*
– WO Larsen: Black Diamond, Mellow Mixture*, Sweet Aromatic*

* Available in The Netherlands

EDIT: I see there is some confusion between English pressed Virginia flakes, cavendish and black cavendish.
– English cavendish is made without the steaming under high pressure in 3 to 4 days.
– English black cavendish is made with steaming the tobacco under high pressure in 1 to 2 days.
– An English pressed Virginia flake, like Samuel Gawith’s Full Virginia Flake, gets about 4.5 hours of steam pressure, then slowly cools in the press overnight. In the morning they take it out. It is still warm then but it has slow-cooled for 12 hours. Golden Glow gets about 2.5 hours of steam pressing before cooling overnight.
So the process of pressed English Virgina flakes is in essence the same as with cavendish. Only the time is much, much shorter.