“Each tobacco leaf should be dyed separately, and not, as some do, after it has been made up into gavillas—small bundles tied at one end of the leaf. It is very important that all the leaves should equally receive the benefit, and this is impossible when several are tied together. The good system of dyeing is used by all practical vegueros; to save labour some do it otherwise, to the great injury of the aroma and quality, and no small risk of the tobacco becoming spotted, and full of holes; for tobacco invariably commences to show these spots and small holes near the heads of the gavilla, where the dye has not been able to penetrate owing to the manner in which the leaves are tied. Each leaf ought, therefore, to be dyed separately, as the most intelligent people do. The leaves should be placed separately in rows on a bench, having all the heads in one line; then the dye should be applied by means of a sponge, which should be soaked in the dye or infusion, and squeezed, so that a dampness only will be communicated to the leaf.
“In passing the sponge over the leaf, it should be drawn from the head or thick part near the stalk, down the large vein to the point, so that the thick vein down the centre of the leaf may receive the heaviest part of the infusion, from which the dye pushes along the transversal veins, and all parts derive benefit from it.
“After dyeing the first layer on the bench, another one is placed above this, keeping always the leaves in the same direction; and this operation is repeated, and each layer is sponged, until the pile from which they are taken is exhausted. As this new pile of dyed leaves gradually increases in height, it should be gently pressed down with the hand, and, when finished, should be covered over with green plantain leaves. This operation should be done in the morning, and by nightfall the tobacco will have acquired the necessary softness, and soaked up the infusion, so that the leaves, although very flexible, will have no signs of excess in moisture. If they have, they should be spread to dry somewhat, because, when the bundles of leaves are being tied up, they should not be excessively wet, as the result would probably be so strong a fermentation that it would degenerate into a putrid one. The leaves should have a soft silkiness, but should have no positive signs of water on them after they have been dyed.
“When the tobacco is in a good state of softness, the next operation is the ‘cabeceo.’ This operation consists in uniting the leaves by the heads—putting them perfectly even, and joining together a uniform number of each class. The leaves should be collected in the palm of the left hand, drawing gently the right hand over all the length of each leaf from the head to the point, and tying them at the heads with a piece of yagua or vine, or, as most people do, by binding one of the leaves round the head of the bundle. This operation is generally made in the evening, and the following morning they should be placed in the bales, as it injures the tobacco to allow it to dry in manojos before putting it into bales, for, if too dry, fermentation is retarded, or is incomplete in the bales.
“We have described the manner of washing or dyeing, in making the gavillas, and tying them in bundles as the most practical vegueros do. In this part we should not, we think, advise any innovation, except that of using old seasoned tobacco instead of fresh for making the infusion, and substituting a decoction made by boiling, instead of an infusion in cold water. But we strongly advise a reform in the sorting and the classification; and a fixed number of each class of leaves should be put in each gavilla, as a basis from which to start all calculations for mercantile transactions. We believe, therefore, it would be convenient to fix, after the following order, the number of leaves which each head ‘gavilla’ should contain:-
| First quality |  | Sound | 25 | leaves to each gavilla |
| Broken or torn | 30 | ” ” | ||
| For stuffing | 40 | ” ” | ||
| Second quality | | Sound | 30 | leaves to each gavilla |
| Broken or torn | 35 | ” ” | ||
| For stuffing | 43 | ” ” | ||
| Third quality | | Sound | 40 | leaves to each gavilla |
| Broken or torn | 45 | ” ” | ||
| Desecho |  | These three classes may be added without counting the number of leaves, | ||
| Fourth quality |  | Suckers | ||
| Sprouts |
but making the heads (gavillas) of a regular uniform size; and the manojos and bales of about the same size as those of ‘sound’ and ‘broken’ of the third quality, the latter weighing 100–125 lb.
“By following strictly this method, and by establishing these quantities and qualities, as a basis for all contracts, any defects found might easily be obviated; and very exact calculations might be made of the number of cigars each bale would yield, after having examined its special condition; and its real value might be estimated either by bales or bundles, or by weight.”
Bulking.—Bulking means placing the tobacco-leaves in heaps for the purpose of heating, in order to develop colour and flavour; this is carried out in various ways, nearly all involving great labour and risk, as in most instances tobacco loses more or less in value during the process called “curing.” The more care is taken in raising the crop, the less attention the tobacco requires in the shed. With a good kind of tobacco, grown on light, friable soil, treated as described, little care will be needed, after the leaves are dried and stripped. By the drying process, the leaves will have undergone a slow fermentation, which makes it unnecessary to watch or guide a regular fermentation afterwards, hence bulking and fermenting, as generally understood, are not required.
After being made into hands, the tobacco is put into heaps (bulked) before it again dries. Every evening, the tobacco that has been stripped during the day is bulked; but if the weather be very dry, it must be bulked as soon as a certain number of hands is ready. The heaps should be made 4–8 feet square and 4–8 feet high; all the stalks are outside, and the whole is covered by mats, &c., to check evaporation. The drier the tobacco, the larger must the heaps be made, to encourage a slight fermentation. The extent of the fermentation can be easily controlled. If the colour of the leaves is not uniform, or if it is desired to give them a browner colour, the heaps must be made large, and a somewhat moist atmosphere is required in the storing-room. This will cause fermentation to set in after a short time, and the heat to rise after some days, so much so that rebulking is required, which is done by putting the top leaves of the old heap at the bottom of the new one. Under such circumstances, the heap must be frequently examined during the few first weeks, to prevent overheating. It is advisable to rebulk the tobacco also, even when not much heated, after the first fourteen days, and again a month later, to ascertain the exact state in which it is. Sometimes the tobacco becomes mouldy; this occurs especially with tobacco which has been manured with chlorides, which cause it to become more hygroscopic than when manured otherwise. If this occurs, the mould must be brushed off, and, if necessary, the tobacco be dried. The tobacco may now remain heaped in the store-room until there is a chance for sale. It must be remembered, however, that the best time for selling varies very much. Some tobacco is fit for smoking a few weeks after drying, whereas others may burn very badly at that time, yet become a good burning article after being stored for several months.