The quest for forum tobaccos – Part 3: Flatlander Flake

The “old” forum tobaccos

In 2012 I started my quest for forum tobaccos. That is, special tobaccos for the Dutch/Belgian Pipe Smokers forum (PRF). That often difficult journey (which you can read about here) ended at the end of 2013 and resulted in 3 delicious tobaccos: an aromatic called Genietmoment, a VaPer named Janneman Flake and a Balkan-blend with the name Brullende Leeuw. All made by a German tobacco company in cooperation with the wonderful Hans Wiedemann from HU Tobacco. After a years rest of the forum tobacco business it started to itch again, I was looking forward to a next phase of the project.

So, from which pipe-tobacco manufacturer would I like a forum tobacco (I already had decided it was going to be only 1 this time).. Sadly not an American company, import-wise that is waaaay to difficult (although I would have LOVED to work together with for example GL Pease, Cornell & Diehl or McClelland). It had to be a European one. On top of my wish-list was the quintessential English tobacco manufacturer Samuel Gawith. But how to get them to participate?

It is said that the secret ingredient for Gawith’s Black XX is Bob’s chest hair..

Actually that was pretty easy. Every year on the Inter Tabac fair in Dortmund I encounter the charming Bob Gregory at the stand of Samuel Gawith (merged together (again) with Gawith & Hoggarth in 2015). On the 2015 edition I took the bold step of asking Bob if Gawith was prepared to make a small batch of a special forum tobacco to be made by him and myself. To my surprise Bob immediately said yes, on the condition that the forum members would buy a minimum amount of 200 tins of 50 grams, and gave me his email so I could send him further details. Yessss, step 1 was taken!

Elbert Gubbels

Now step 2, getting the tobacco legally in The Netherlands. Gawith did not have a Dutch importer but I knew that someone was very interested in that job: Elbert Gubbels of Gubbels Pipes (Big Ben etc.). After years of being busy with smoking pipes Elbert was looking for a business expansion with pipe-tobacco. Fred and I made sure to let Elbert know that working with a high quality pipe-tobacco manufacturer such as Samuel Gawith was a smart move. He agreed with that and assured us he would talk to Bob about importing Gawith tobaccos to The Netherlands. In short, the next phase of the project could begin!

Back home I immediately mailed Bob, I already had an idea in my head of what I wanted. With the last forum tobaccos the high seller was Janneman Fake, a VaPer and a kind of blend that appealed to a lot of forum members. This time I wanted something similar yet different. First the cut, not a flake but a plug which is more special. Further I am a big fan of oriental tobaccos so I thought, Virginia/perique/oriental.. Hmm.. That could work! Also I was inspired by a blogpost by GL Pease about his wonderful Embarcadero blend. There he admits using a pinch of latakia in his Fillmore offering. A trick to extra season a tobacco, the same as someone would season a good steak to make it an excellent one.

So I wrote to Bob that the ingredients should be Virginias (in the vein of Full Virginia Flake), orientals (sadly Gawith only has an assorted blend of orientals and no specific varieties), a bit of perique, a smidgen of latakia and I told him what, very roughly, the levels of the different tobaccos should be. I was going for a sturdy yet mild, exotic and not overpowering blend with some fine nuances. Now I hear the PRF members saying: “What?? There is latakia in the new forum tobacco?? You said there wasn’t!” True, I lied, I admit and I am sorry. Because some members don’t like latakia I was afraid that they would not buy the tobacco simply because the dark leaf was an ingredient (although used very, very sparsely). So all you latakia haters who now smoke the blend and love it: got ya!

Bob being busy

While I was waiting for an answer from Bob I made the list on the forum where everyone could sign up for the tobacco. Remember, we had to order a minimum of 200 tins and I was crossing my fingers to say the least we made it to that amount. I did not need to worry. On 20 September 2015 forum-members could order and on the 25th I already had my 200 tins! In the meantime Bob had been busy with the plug: Dear Arno, this morning we made a trial cake of tobacco. This will be baked tomorrow and then we will test the tobacco for 7 to 10 days. After that time it will be cut and samples sent to you. The 25th I informed him that we managed to cross the 200 tins border. That is very good news Arno. I will now go downstairs to the production area and see what the cake is like. (10 minutes later) Interesting!!! The cake is made and the aroma is intriguing. I have cut a plug and will send to you for your opinion. Please allow it to dry a little as the tobacco is still very young.

Sample-round 1

On 22 October 2015 a package arrived at the office for me. Hmm, rather large, I thought, can’t be Gawith, such a box for only a sample? But the sender was indeed Gawith and inside was a massive 250 gr. slab of pressed tobacco! Wow! With the previous forum tobacco I only got small sample bags of which I could barely smoke 4 pipes. At least I could provide decent samples for my testers this time. So I cut the tobacco up in smaller pieces and send them to my testing panel, a select group of forum members and friends. Of course I also smoked the plug and to my relief it already was pretty good. In short the testing panel and I came to the conclusion that the plug was ok, the basis was good. So I mailed Bob that the Virginias in combination with the oriental, perique and smidge of latakia were to be found very interesting taste-wise. However, halfway the bowl it seemed that the “middle” taste-tones were lacking a bit. The plug had good “subtones” and “overtones”, but the middle was a bit “empty”, sort of. Like someone of the testers said: neither fish nor fowl. So I suggested an increase of the level of Oriental to Bob to fix this. The perique level was ok but the latakia could be even less. By the way, I did not tell the testing panel it contained latakia but some detected it.

Sample-round 2

It took some time before Bob responded, on 23 November he send this: Arno, I have noted your comments and will work at it. For now we are extremely busy, so if you do not mind, Arno Plug will have to go on to the back burner. Be assured that I will take a long look in a couple of weeks. About the name “Arno Plug” were some funny comments on the forum, I don’t understand why.. Finally at the beginning of February 2016 the second sample-slab of tobacco arrived at the office. But when I smoked the first pipes I was not happy.  I asked Bob to raise the oriental content but now the blend was really lacking midrange taste, my fault. The Virginias no longer supported the oriental so the whole balance was off. From the other hand the perique and latakia content were perfect. Still I did not send this sample round to the testing panel, it was not better as the first one. I mailed Bob my findings and waited again.

Then it began to rumble about the cut of the forum tobacco. It was going to be a plug but Gawith was slowly beginning to object to this: Regarding the packaging of SG plug, we have one packing for this in the UK and that is a 250g box. Generally speaking, it is very expensive to cut a plug to 50g, it requires constant trimming to size and we end up with excessive waste, the cost of which has to be added back to the end product weight. We can do this in a tin but the price will shock you. Can the product which you require not be taken in the standard 250g box? It would certainly have a more attractive price for you. You could of course also take the product as a bulk product and pack it yourselves. I told Bob that we could not take the standard 250 gr. box or the tobacco as bulk. This because in The Netherlands no sales of bulk tobacco is allowed, only sealed tins and pouches are permitted. On 8 March the final verdict fell: Dear Arno, with regard to the Forum tobacco, we are not prepared, on the basis of time/cost to pack this product as a 50g Plug. We are, however, prepared to go with a 50g flake product.

Flatlander Flake

Damnit! I already “sold” over 200 tins as a plug and now it suddenly was going to be a flake. I explained the situation to the forum members and asked them if they were willing to accept the new cut. Luckily the most heard response was: “A plug is more special but a flake is also ok, easier to handle”. *Pheww*! Only 1 member wanted to cancel his order because of this. The new flake also needed a name so I asked the forum members for suggestions. The best came from Jef (nickname NoneNicer): Flatlander Flake. He was inspired by the book “Flatland, a romance of many dimensions” written by Edwin A. Abott. The book is about dimensions and we just went from 3D (a plug) to 2D (a flake), very appropriate. Plus that when I read the name I immediately got inspiration for the tin artwork. I asked Bob what the dimensions of the label were and started to work. I ended up with a picture of the flat lands around the village where I live. With some Photoshop I made it look like a painting. I added the Samuel Gawith logo, some info, of course the name, send it to Bob et voilà, I was ready.

Bob still had not send a reply but after some pushing from my side he finally did on 4 April: Dear Arno, I have no news as yet. I have to wait until Mr Gubbels enters into an agreement with Gawith Hoggarth. Until this happens I cannot make or ship. This may not happen until after May 20th in which case I may have wasted money on labels we cannot use. Until I know what the market is doing I will not move. I know this is frustrating but the problem is small compared to our having to change label designs and health warnings for all EU markets, also to possibly change the type of tin we use. The problem at which Bob was pointing was the new tobacco regulation guideline TPD2. That required that Flatlander Flake had to be produced before 20 May 2016 otherwise we 1. could throw away the labels that were just made and 2. horrible pictures would be put on the tins. Luckily a couple of weeks later Elbert Gubbels committed himself to Gawith. He was going to import several Samuel Gawith tobacco to The Netherlands including Flatlander Flake. But our troubles were not over yet.

An example of TPD2 approved artwork…

A silence fell until 10 June when Elbert mailed me: Dear Arno, an update regarding tobaccos from England: I have just been in contact with Bob Gregory and an appointment is scheduled in Kendal. After much hassle we finally have the permit to buy tax seals. We hope to be able to import tins with no unsightly pictures on front and back. Regarding the status of your forum tobacco order: this will at least have to get the ugly pictures because the tobacco is not yet manufactured / packaged. All tobaccos produced after May 20 this year are obliged to get the pictures on the cans. It all goes not smooth. Of course there is the fact that we have received permission / a license so late. Bummer, artwork with nasty pictures.. “Oh well, at least a forum tobacco is coming!” I thought.

Respect for this man!

The next months Elbert got busy with the whole process of importing the Gawith tobaccos. Which was hell for him. This because it was the first time he did anything like that. Only a few companies import tobacco into The Netherlands so there was no one who told Elbert what to do, he had to find out everything by himself. You have meet all kinds of bureaucratic requirements and every time Elbert thought he saw the light at the end of the tunnel our dutiful civil servants conjured up another wall. Very frustrating so I have nothing than the utmost respect for the man because he stubbornly kept going on. In the mean time I discussed the final number of Flatlander Flake with Elbert, he would import 300 tins.

Yeahh!! No gruesome images!

Things started to move again when Bob asked for the Flatlander Flake artwork, again, at the beginning of August. A good opportunity to ask for the 3rd sample round but I got no response. Halfway September was the Inter-Tabac Fair in Dortmund so I mailed Bob several times and begged him to bring new Flatlander Flake samples, again no response. As you can read in the corresponding blogpost the bastard (love you Bob!) did bring 2 tins of the final product with him (No more sample rounds, he said..). I noticed the content of the tin I opened was still very fresh but I tasted potential! I have to reluctantly admit I could hug the man at that moment. In October one of the big PRF meetings was held in Heukelum and only just before the date I received 2 sample-tins from Elbert, with the new artwork. To my amazement and delight it did not have the gruesome images, only text warnings. How they did it, no idea, but to be honest I don’t care.

Tax seal

Slowly the date that the forum tobaccos arrived in The Netherlands was getting closer. Tobacconist Willem Schimmel in Zutphen was doing the sales, as an importer Elbert Gubbels could not do that. At the beginning of December Willem rang me up: “I received the tins, but there are only 288 of them..” What!!?? I ordered and “sold” 300 so I was 12 tins short. I phoned Elbert to asked what happened. Apparently he had send the mandatory tax seals to Gawith so they could attach them to the tins. Only, those seals come on rollers of 144 pieces. So 2 rollers of in total 288 tax seals were received and processed by Gawith. The 12 remaining tins they had send to The Netherlands without anything on them. Which was discovered by our hard working customs office.

Burning Flatlander Flake the wrong way..

They phoned Elbert and he went like “Oh sorry, perhaps I can pay the taxes for them now? I mean, it is only 12 tins.” At which the customs office burst out in anger and even threatened to call the police on Elbert.. In the end he was forced to burn those 12 tins in front of 2 customs officers who especially had to come to the Gubbels factory, I kid you not ladies and gentlemen, I have photographic proof of that. Totally insane, like those tins contained hard drugs! Luckily Gawith had some leftover stock of Flatlander Flake. Just before Christmas Willem organized 3 days on which the members of the forum could pick up their forum tobacco tins and the rest would be send by post. I was there on one of those days and the ambience was just great: happy forum members, Willem played the role of gracious host, there was a cosy Christmas market in the centre of Zutphen, finally all was well.

So now you probably all expect a glowing review by me about Flatlander Flake. Well, in The Netherlands we have a saying: “Wij van WC eend adviseren WC eend. (We from Toilet-Duck (a company) advise Toilet-Duck)” We Dutch use the slogan any time people or companies are clearly recommending their own stuff. I won’t do that, the lucky ones who have obtained a Flatlander Flake tin have to make a judgement for themselves. I can only say that I am very happy with the final result, I think it is a unique flake, especially within the Gawith range. It is interesting, smooth and mellow with grassy, sweet candy-cane-like tones yet the perique gives it some peppery kick which is rounded off by a slight smoky after-taste by the pinch of latakia. You can smoke it in all kinds of pipes where the shape of the bowl defines which ingredient comes out more. For example billiards enhance the Virginias and pots/princes the oriental content. However I do advise to smoke slowly, almost sip it. If you have the patience to leave the tin shut I predict you will be in for a treat after some time. Virginias and orientals age very well.

I would like to thank Bob Gregory, Elbert Gubbels and Willem Schimmel, without them Flatlander Flake would not have been possible. Also I thank my girlfriend Ellen for enduring my moods and billows of smoke. And of course I thank all of you forum members who have bought the tins (sometimes vast amounts!) without knowing what the final product was going to be like. Thank you for having faith in me!

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The quest for forum tobaccos – Part 2.

Hans Wiedemann

Hans Wiedemann

Fasten your seatbelts ladies and gentlemen. At the time I wrote part 1 I never, ever expected that there would be a part 2 of my quest for forum tobaccos. I just experienced too many disappointments and thought that it would all end in nothing. But…. As you can read in the last response at the bottom of the page Hans Wiedemann from HU Tobacco once again took pity on me and helped me out. Once again it often was not smooth sailing, but we persevered and in the end overcame all obstacles.

PRF 5 jaarSo, to refresh our memories, why the forum tobaccos? Well, this year the Dutch/Belgian Pipe Smokers Forum exists 5 years. Because of that last year the idea arose for some special forum tobaccos to celebrate the jubilee. 3 tobaccos to be precise, a latakia mixture, an aromatic and a Virginia flake. Of course I had to open my big mouth and I became responsible for the creation of those tobaccos and the artwork. Why? Because it is a dream of me to see a blend which is created by myself is made available for others. And that is more difficult than I thought..

wowA lot of things were possible with Hans BUT only if we were buying 50 tins of 100 gr. per sort. So that is 150 tins in total! 15 kilo! I thought that the forum-members would never buy such an amount. Deeply disheartened I explained the story on the forum and asked how many tins the members were willing to buy. This because I had to have to money upfront. No Rudi this time to buy all the tobaccos and later see how he would sell them. To my utter and absolute amazement within only a couple of hours the amount of 50 tins per sort was reached! The next days the quantity kept growing. And that without knowing an exact price or having the actual blends! In the end 73 tins of the aromatic were ordered, 109 tins of the latakia and a whopping 116 tins of the flake. A total of 298! 29,8 kilo of tobacco! Wow!  Unnecessary to say that Hans and I could continue. The role of Hans would be that of advisor and mediator between myself and the tobacco factory he sometimes worked with. I was responsible for pretty much everything else. The creation of the blends, the artwork, collecting the money from the forum members and the distribution of the tins.

800px-DunhillLightFlakeRound 1. My first idea for the flake was that of a light Virginia flake in the vein of Orlik Golden Sliced, Dunhill Flake and Capstan. So I asked for a light natural Virginia flake with only a slight topping of tonka-bean and even less orange. Unfortunately the tobacco factory thought this was to be the aromatic so they applied way to much of the topping. Hans first got the sample and well, he did not like it to say the least.. Also the tobacco factory were not happy with having to add an aroma to a flake. It would not work they said. On top of that the first samples Hans send to me to my home address did not reach me and got lost in the mail..

1Round 2. From this time on Hans decided to send packages to my working address. That way we both know they would arrive. In the package I got were 3 flakes, 3 aromatic samples and 3 latakia samples. Let’s start with the flakes. Because the application of an aroma on a flake was not a good idea I had to choose between several already existing flakes. The first one I smoked was bland and uninteresting. The next couple of flakes were pretty decent but had the same problem: they were available here in The Netherlands.. So I had to step off the idea of a light, pure Virginia flake. I told Hans to search for a flake, as long as it did not have latakia, that was not available here or too well known in these parts.

Vanilla-LatteFor the aromatic I had already mailed several ideas to Hans which were translated into 3 samples: 1. Black cavendish, burley and bright Virginias with an aroma of coconut and vanilla. 2. Black cavendish, burley and several Virginias with an aroma of passion fruit and ahorn. 3.  A lot of Black cavendish, bright Virginias and a bit of burley with an aroma of coffee and vanilla. I smoked all the samples and could not find a clear winner. So I send some samples away and let a couple of folks smoke them. All had the same favourite, the one with coffee and vanilla. But for me it lacked a certain punch, it needed some more aroma.

LatakiaI mailed Hans some ideas for the latakia mixture and he mixed two samples himself of which he thought I would be satisfied with. The third sample was mixed by the tobacco factory after an idea of Hans. Before the samples were send through to me Hans already smoked the factory sample and he was raving about it which made me feel very positive.. ..Until I smoked the actual sample. It tasted bitter and I did not like it one bit. Having learned my lesson with the aromatics I send away some samples hoping for some sound opinions. After all, my taste is not the taste of everyone. When I received the feedback it became clear that the blend indeed was too bitter. To make things worse I also was not impressed with the samples Hans made himself. Solid and well crafted blends, don’t get me wrong, but nothing special. And I wanted something special. So at the end of round 2 Hans and me were not happy men. We still did not have a flake, the aromatic was not good yet and the latakia mixture also was not up to par. In the end we tried to be as positive as possible.

2Round 3.  I received 2 flake samples which were not available in The Netherlands. Hans already had smoked both and very much liked one of them. I also tried this one and indeed, it was absolutely superb! The other one was pretty good but that was it. To be 100% sure I once again let people smoke from the samples and luckily everyone opted for the one Hans and I were enthusiastic about. With the flakes we had a very clear winner, yeah!

OLYMPUS DIGITAL CAMERAWith the aromatic the tobacco factory had a slight problem. They could not boost the aromas they had used any further, they were at their maximum. Whaaaat?? Luckily they opted for some other but similar tasting aromas. Those were of higher quality but also more expensive. Well, so be it. I had already decided to not cut down on the quality of anything regarding the tobaccos. When I received the sample I could not have been happier. Exactly what I wanted, here we also had a winner, I liked it very much!

Plan BWhat I did not like was the new latakia mixture sample. For me it looked, smelled and tasted not special enough. Luckily I had a plan B. I once smoked one of the house-blends of a German tobacconist and I absolutely loved it. One of the best latakia mixtures I ever smoked. Period. So I asked Hans if he wanted to inform if we could use it as a forum tobacco. And we could! BUT I had a big dilemma now. I already told the forum that the flake was an existing one but that the aromatic and latakia mixture would be unique blends. Now the latakia mixture was available somewhere in Germany.. I needed some advice about what to do and found it by some friends from the forum. They said I should be open about it and let the forum decide if the project should stop or go ahead. So I opened up to the forum members and clearly explained the situation. Thankfully the vast majority (you can never please everyone) was very understanding and said I should go on.

moneyYesss!!! I had 3 winners! Now the financial part. I am very straightforward and told Hans immediately very clear what kind of price I wanted for the tins and why. Well, I offended him bigtime by doing it this way.. It took me a lot of e-mails to smooth things out between us. A lesson well learned. Needless to say we got the tins for a very good price thanks to Hans. I could have made a bit of profit on the tobaccos but I decided to keep them as cheap as possible.

7I got busy creating the artwork, collected the money from the orders of the forum members and relaxed a bit. I send the finished artwork to Hans who would send it through to the tobacco factory. He also arranged some blank sample tins for the Heukelum meeting. I printed the labels at my work and put them around the tins. Absolutely stunning! Just before the meeting I got the sample artwork which was printed by the tobacco factory themselves. Compared to my own prints it was a bit grainy and dark. Still ok but I am a perfectionist, it was not up to my standards. The thing was, I forgot to ask Hans how we should do things with the labels and Hans forgot to inform me that we were better off printing the labels at a professional printing-company. Another lesson well learned. Now I luckily can perfectly live with the printed labels.

So, FINALLY here are the 3 Dutch/Belgian Pipe Smokers Forum tobaccos:

P10607532

Genietmoment

GENIETMOMENT
Contents: Black Cavendish, Golden Virginia, Burley
Flavouring: Coffee, Vanilla
Packaging: 100g tin
Tin description: Create an enjoyable moment for yourself with this high quality mixture, consisting of Black Cavendish, Golden Virginia and a bit of Burley topped with an aroma of coffee and vanilla.
GenietmomentBackground information: One of my ideas for the aromatic forum tobacco was to do something with coffee. I come from the Dutch province of Noord-Brabant where taking the time for a nice cup of coffee is common. But a coffee flavour is very difficult to incorporate in a tobacco because it has a tendency to dominate. Despite Hans and myself were successful in creating a delicious mixture by the addition of some vanilla. The main ingredient is Black Cavendish (also typical Dutch) with some Golden Virginia added and a bit of Burley. The inspiration for the artwork I got from coffee and beautiful women. Both enjoyable for most men. I also found it nice to put a woman on the cover because of our female forum-member, Monique (Milleluci).

Janneman Flake

Janneman Flake

JANNEMAN FLAKE
Contents: Brown and Red Virginias, Perique
Flavouring: None
Packaging: 100g tin
Tin description: Pressed brown and red fire-cured Virginias, full and soft of taste, are cut into long flakes and together with a pinch of perique, to round off the whole, they provide a fitting tribute to the “pater noster” of the Dutch/Belgian Pipe Smokers Forum: Janneman.
Janneman_FlakeBackground information: On the PRF Rotterdam-meeting last year we talked about forum-member Janneman, that he meant a lot to many starting pipe smokers. Many folks of the forum got there because of the movies or Pijpenboek from Janneman. Would it not be nice to honour him with something? We asked ourselves. At that moment the whole forum tobacco story had just begun so I said “Isn’t it  a nice idea to honour Janneman with a forum tobbacco?” Everyone agreed and I kept the idea throughout the whole journey. So Janneman, thank you for inspiring many of us! The flake itself is very natural, full and interesting of taste and contains Red Virginias, firecured Brown Virginias and a bit of Perique. The artwork stands for another hobby of Janneman: flying of kites.

Brullende Leeuw

Brullende Leeuw

BRULLENDE LEEUW
Contents: Light and Red Virginias, Latakia, Oriental, Black Cavendish, Perique
Flavouring: None
Packaging: 100g tin
Tin description: The exquisite balance of this exotic mixture stands for the unity between the Dutch and Belgian Pipe Smokers Forum members. That together many pipes may be smoked!
PRF_Tabakken_K&K.inddBackground information: Like I already told,when it became clear that the latakia mixture was not according to my standards I decided to fall back on Plan B, using an already existing supreme quality tobacco. I immediately knew which one I wanted, I did not know if I was able to actually get it. And luckily I could get it. The blend is beautifully balanced with light and Red Virginias, Latakia, Oriental tobaccos, some Black Cavendish and a pinch of Perique. For the artwork I was inspired by the unity of the Belgian and Dutch forum members. The lion stands for a nice shared symbolism, thus the name “Brullende Leeuw” (Roaring Lion).

The forum tobaccos are available for everyone at the webshop of HU Tobacco.
For your information, HU Tobacco also ships to the US and other countries. For questions please e-mail Hans Wiedemann, he speaks English (and German of course): hu-tobacco@t-online.de

Kind words of Hans to the forum who sums it all up pretty well

Kind words of Hans to the forum who sums it all up pretty well

Last but not least I want to thank:
– Hans for the wonderful cooperation, without you this all would not have been possible!
– The members of the Dutch/Belgian Pipe Smokers Forum for being a great bunch (thanks for the whisky!) and having faith in me.
– The tobacco testing members of the forum who’s opinions and advice about the tobaccos and other things have been very valuable to me.
– The forum tobacco distributors in The Netherlands and Belgium, you made my work a lot easier.
– My dear friend Ed.
– My girlfriend Ellen for her everlasting support <3.

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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.