How do cigars in Russia
Did you know that half a century ago, the Russian Empire was one of the leading powers in Europe cigar? Then produces 150-200 million cigars a year, is the amount of cigar production in Cuba. Cigars were exported to Europe and valued for the taste and quality.
For many it will come as news, but cigars are produced in Russia now. Pogarskaya cigarette and cigar factory will soon celebrate its centenary and is currently the only company in our country, producing cigars. We have a rare chance to see the inside of a factory.
The factory was built early last century as a branch of the Riga "Koffsky & Kunchczynski" Alexander von Rutenberg. Reason for the discovery was not the desire to expand the production and the beginning of the First World War. To hedge the business, part of the production has been moved away from the front line.
Today, looking at the Bryansk region, it is difficult to imagine that a hundred years ago this land marquee way to grow good tobacco. Dozens or even hundreds of acres of tobacco fields cover the gauze. Under it was generated microclimate necessary for aging of first grade of tobacco with an elastic sheet and a thin vein.
In the year of going about two million pounds (320 tons) of top-quality tobacco. Part processed at factories in Pohar and Riga, but the bulk was exported, the famous tobacco fair in Bremen.
Shortly after the opening of the factory there was a great October and the company, together with farmland, passed in management to the labor class. Tobacco is immediately stopped growing, there were shortages of raw materials and factory nearly stood up.
Let's look at the production process, and the story I dorasskazhu later. Let's start with the most simple and inexpensive: with cigarettes and cigarettes. Here tobacco enters the conveyor. He rastrushivaetsya (bagged and baled tobacco comes slightly compressed), mixed, chopped and fed into a special drum.
It resembles a horizontal rotary kiln for cement production, but less than the other. There tobacco is dried, cut, moistened, flavored and further stirred.
modern equipment, but there are a lot of "dinosaurs".
This is such a ready stream of tobacco fed to the loading and shipping in the shop. Of course, we can not look inside the drum, though, I'm sure there are a lot of interesting things.
The factory produces almost all types of tobacco products. None except that the chewing and snuff. "White Sea" and "Accept" then began to produce after the Great Patriotic War. The demand is there and release them until now, a "Prima" more than a dozen species.
Let's start with something simpler. The structure of cigarettes knows probably everyone. The sleeve of thick paper approximately 2/3 of the length, top tissue paper, 3.1 parts tobacco.
In the photo there is a paper for filling cartridges. In the same machine goes cigarette paper and tobacco.
The output is the finished cigarette. You know how tobacco is inside? Probably you know, but I recall. A certain amount of tobacco fed into the machine in a cylinder, the cylinder is inserted into the preform and simultaneously a cigarette with recovery of the cylinder is extruded tobacco. The concept is simple. One minute in this way about a hundred stuffed cigarettes.
Next uncomplicated packaging and ready, a pack can be guided in Karelia.
C "Prima" is still easier, the sleeve is not needed there, that line we will miss. Let's look at the production of filter cigarettes.
And watch something special and nothing. A huge machine for the production of, and a couple for the package. According to the pneumatic tobacco is fed into the machine, there also is charged with paper and filters. And at the exit ready cigarette.
A lot of cigarettes. They are placed in special boxes, trays and transported to the next machine.
On this machine there is rejection and packaging boxes.
Viewing window for rejection. Workers in the course of determining the defective cigarette and withdraw it from the total flow. When I pulled this one. How to distinguish them in a continuous stream, for me it remains a mystery.
standard 20 cigarettes wrapped in foil, cardboard or paper packaging and cellophane. Done!
I tried to find out the percentage of smokers in the workplace. It turned out that no such statistics are not kept, although it is recognized that the likely percentage above the national average. Maybe the point is that as in any production you can not make products, but to use it on the premises is not prohibited. It is clear that this only applies to cigarettes and cigarettes.
In spite of this, some people prefer the products of competitors. The taste and color ...
And we come to the fun part: to pipe tobacco and cigars. In the picture the different tobaccos from Cigarette cut to almost black Cavendish. In fact, the types of tobacco of course a lot more than four.
Now the production is completely tied to imported raw materials, even paper bought overseas. Tobacco either buy from reliable partners, either on the same tobacco fair in Bremen. Tobacco is purchased, probably from all the countries producing it.
Past large chests for aging pipe tobacco we go down to the cellars.
In addition to the existing air-raid shelters for the seven seals there is a room for aging cigars. It looks more like a warehouse, therefore, dwell on it, we will not.
A will go immediately to the far room, where, under the yoke of "marry" flavored tobacco blend, made of recovered recipes of the last century.
As you can see, seemingly nothing tricky. And the mixture is placed under a press for better mixing of odors and flavors. Smells in the room, I must say, really magic. I have long given up smoking and do not like cigarette smoke, but the crude pipe tobacco smell delicious.
In the room to maintain a certain climate.
After tobacco otlezhus under pressure or in the bin allotted time, he was sent to the packaging. Although some are sent by another press and make such utter tobacco washer. Then the tobacco lover will pinch off from this washer on a slice and smoke in the tube.
This is the first girl who smiled at me in the factory. She has an important task: to each jar put so much tobacco as necessary. And not to be mistaken or per gram.
Bankozakatyvayuschy apparatus similar to the consumer, but instead of the three-liter jars with cucumbers small jar with a mixture of tobacco.
There is also packing in briquettes. Generally, Pogarskaya factory can safely boast that almost all the work with expensive hand-manufactured tobacco. Look, even the excise tax and the "Ministry of Health warns" not glued to the machine.
In the next room are packed ready tobacco blend for hookahs. There's quite boring: there are tanks with different mixtures, insisted on natural syrups. Species of these mixtures some just unreal amount and regularly appear new.
Here, finally, the purpose of my visit! Cigars and sultry mulatto twisting their hips in their chocolate! Girl like you in cold Russia?
However, my enthusiasm was immediately cooled down. No there is no mulatto and twist cigar is not on a flat solid surface is unreal.
A tale about a mulatto we must Prosper Merimee. It seems like he had a sultry girlfriend, that joke's really cool he semblance cigarillos.
Oh well, no mulatto, so at least in the process of look. Especially in Europe, this can be seen only in Pohar, but in a small factory in Seville.
Tobacco cigar comes in dried leaves, stripped them, and then there is a culling process. Everything is done by hand. It is impossible to put a cigar in sick or damaged by insects leaves. Immediately remove the central vein.
Entire and beautiful leaves will both cover sheet (topsheet face cigars) bit, "terrible" serve as forming the wrapper with mechanical defects are to stuffing.
Twister / krutilschitsy cigars called torsidorami. In general, originally it was a male profession. Cigars are from a single sheet of cut and. First, look at the manufacturing cigars, shredded leaf.
Who has ever seen a machine work Cigarette immediately understand the principle of operation. All the same, only instead of paper used tobacco leaf.
Cigars from whole leaves swirling in the same way but there is a nuance in the assembly. inside the wrapper leaves are put three or more types of tobacco. The proper selection, density, uniformity depends on the taste of the future cigar.
Then the cigars are placed in oak mold. They smoothed out all the irregularities of the tobacco leaves. In these forms the cigars are long, a couple of hours.
The last stage of cigar birth: it falls on the table to torsidoru. toolset nemudreny: oak board, blade called chaveta and a small guillotine cigar to give the required length.
The cover sheet is cut on tricky circuit, and, each type of cigar has its own circuit.
The cigar very carefully wrapped in a wrapper. It should not be folded, or torn places.
From the remainder of the cover sheet is made that some kind of cap on the end of the cigar. That's all the cigar is ready. She is still waiting for a long confinement in the cellars of the familiar, in order to mix the tastes and smells it.
But the second girl smiling at me. In general, the production of very serious with serious protection of their secrets. I do not even tested at the Defense Ministry, but there is something so I shot the holy of holies.
I understand what you're younger, the less responsible job of twisting you to stand out. Cigarillos do much easier and less full of cigars responsibly.
Experienced torsidor per shift makes about a hundred cigars or cigarillos four, and in the year the company produces about two million both. Before the Revolution volumes were ten times more.
During the Second World this area two years has been under the occupation, but the production is not stopped. The workers went to the front, more precisely, together with the front, but the Germans somehow managed to organize a normal operation of the plant. Then there were the difficult post-war years, it was then started producing cigarettes and "Prima" filter cigarettes, cigars output reached 7 million a year, and they are supplied to all the countries of the socialist bloc.
In the 90's the company somehow lucky and it is not covered, as many other enterprises. Likely helped the same notorious "Prima". Reduced staff, reduced and production. Ceased to produce cigars, fully switched to a budget consumer goods.
In the late '90s, the company joint-stock company at the center stood Doctor of Technical Sciences, Professor Igor Moiseyev. His contribution can not be overestimated: a dying unprofitable company has become one of the leading in the region and among the ten largest in Russia for fifteen years. As far as I know, the company is not included in any of the multinational corporations and is completely self-sufficient.
As I mentioned, today the factory produces almost everything that can be made of tobacco: cigarettes, cigarillos, tobacco for hookah, pipe tobacco, tobacco for hand-rolled cigarettes, cigars. Most of all, I forgot something. The plans of further development, but this is a commercial secret, I will not be distributed.
The whole evening we sat for a conversation with Igor. He said basically it affects a lot of experience teaching at Moscow State University of Food Production, and I sat there with my mouth open and listened, occasionally asking questions. We had to write down what he told me to get a short course in tabakovedeniyu and history of smoking, and tabakonyuhaniya tabakozhevaniya.
As with any subject, when you talk with a professional, truly love their work, you start to look differently at many things. I fell out of love smoking long before he dropped the case, but now I think I understand people who enjoy good tobacco.