Cigar Solutions


environmental control to preserve your tobacco and cigar quality


Our Solutions - We'll bring Havana to you!

Aguair's engineers will work with you to develop solutions that will preserve your tobacco and cigar investment. Our humidity control and air sanitization systems will ensure you can precisely dictate the conditions in your environment.
growers
processing
storage
retail

Growers

Tobacco is farmed from the tropics and the subtropics to temperate latitudes such as the Mediterranean. Tobacco leaf consists of the dried and fermented leaves of the tobacco plant. The two major popular tobaccos commonly consumed today are Virginia tobacco and wild tobacco. Wild tobacco is a blend of Oriental, Asian and American tobaccos. The first step in tobacco processing is the harvesting of the tobacco leaves.

In order to have the best quality tobacco leaves for further processing, the leaves should have moisture content between 12-16%, so an ambient relative humidity of 60 to 68% is required to maintain equilibrium.

The next step is curing and fermentation which is crucial tobacco ripening processes. Curing process allows slow oxidation and degradation of carotenoids which allows the tobacco to take on properties that are usually attributed to the “smoothness” of the smoke. There are two distinct curing methods, one way is natural curing under the sun and in the air whereas in artificial curing heat produced by man-made source, such as fire or hot air.

The next step is fermentation where there are also two options as well, one being natural and the other being chamber fermentation. The final stage of the production process is the aging where the content of the aromatic substances is markedly increased.

In order to have the best quality tobacco leaves for further processing, the leaves should have moisture content between 12-16%, so an ambient relative humidity of 60 to 68% is required to maintain equilibrium (defined by sorption isotherm). Additionally, humidifying without wetness is even more critical to a safe mold free environment. Aguair's Aguatronics™ humidity control system is ideal and is engineered specifically for these types of situations. Its automated control panel keep humidity at specified set levels. While consuming the least amount of energy compared to any comparable humidity system is the market. The Aguatronics™ Canon nozzles are specially designed for commercial application, like this tobacco curing. They produce a high momentum, dry (6-10 micron) fog and put out 0.5-1.0 gallons per hour of relative humidity by volume without any moisture saturation.

During the curing and fermentation process ClensAir™ and SaniCart™ would also be very useful equipment to have on hand. The humidity rich environment and food source can host all sorts of microbials, bacteria, pathogens and mold. Surface and air sanitation can really improve the overall integrity of the leaves.

Aguatronics™ tobacco harvesting ClensAir™ tobacco curing Sanicart™

Processors

During this stripping process the conditions should be about 70-75%RH and 24-29°C in order to prevent the tobacco from drying out.

After the curing and fermentation, the tobacco leaves are packed and transported to a cigar production or manufacturing facility. This transportation process causes the leaf bales to become extremely dry due to lack of humidity. One of the initial processes, often referred to as softening, involves the tobacco leaves passing through a high humidity and high temp chamber. The softening process continues as the leaves are staged in a high humidity of 85-88%RH (relative humidity) at 30-32°C environment. During this process the tobacco will increase in moisture from about 1-2% to some 24% moisture by weight dependent on the client requirement.

After the tobacco has been softened the stems of the leaves are removed. During this stripping process the conditions should be about 70-75%RH and 24-29°C in order to prevent the tobacco from drying out. The tobacco then undergoes its final process in this area, casing and conditioning, where it is flavoured. In most production plants the tobacco will leave the Primary area with a moisture content of between 13-16%. This requires an ambient equilibrium humidity of between 60-68%RH to prevent moisture loss.

In all instances of the production process, Aguair's Aguatronics™ humidity control system can help maintain ideal humidity. Its patented nozzle design is engineered specifically for these types of situations. Its automated control panel keep humidity at specified set levels. While consuming the least amount of energy compared to any comparable humidity system is the market. The Aguatronics™ Canon nozzles produce a high volume, dry (6-10 micron) fog and puts out 0.5-1.0 gallons per hour of relative humidity by volume without any moisture saturation.

The staging and production require high levels of relative humidity. However, the relative humidity can become excessive. Since tobacco leaves are highly hygroscopic, they absorb as much water vapor as sustainable that they become a nutrient medium for molds. Mold, mustiness, mildew stains and a musty odor reduce the quality of the tobacco. This also directly impacts the bottom line and profits. Aguair’s Clensair™, patent pending 6-stage air purification technology utilizes latest UV and photocatalytic disinfecting technology combined with advance media filtration to provide 99.9% clean air. It uses 6-layer purification process ensures all microorganism, molds and pathogens are eliminated. This helps maintain the integrity of the cigar and smoke. It also helps protect the health of the production workers.

tobacco stripping Aguatronics™ cigar rolling ClensAir™

cigars
cigars
cigars
cigars

Storage/Warehousing

After the production process, the cigars are wrapped in bundles and warehoused. During the entire storage process, it is still crucial to maintain temperature and humidity. Cigars are hygroscopic, and they can quickly absorb or lose humidity based on relative humidity in the storage environment. They require a relative humidity of approximately 68-74% for optimal flavors to evolve. This level of humidity also supports an even burning of the cigar.

Cigars stored in lower humidity conditions can become dry and fragile. Cigars are meant to burn slowly and evenly. At low temperatures, however, dry cigars burn faster and hotter due to their low moisture content. Essential oils prematurely evaporate under low humidity conditions, eliciting an aggressive and slightly bitter taste, and unpleasant smoke.

Aguatronics™ humidity control system can help maintain ideal humidity. Its patented nozzle design is engineered specifically for these types of situations. Its automated control panel keeps humidity at specified set levels while consuming the least amount of energy compared to any comparable humidity system is the market. The Aguatronics™ Canon nozzles produce a high volume, dry (6-10 micron) fog and put out 0.5-1.0 gallons per hour of relative humidity by volume without any moisture saturation.

Cigars that are stored in high humidity levels absorb excess moisture, resulting in swelling of tobacco leaves. This results in uneven burning of the cigar, excessive smoke, and a heavy, acidic flavor. Extremely high humidity also leads to rotting and mold development on the cigars.

Mold is a huge concern in the cigar industry. Ideal storing temperatures and humidity create a perfect breeding environment for mold to colonize on cigars. Once mold has settled on the cigars it must be immediately discarded as it can lead to serious health effects for the consumer. Additionally, once mold has colonized on the cigars starts to release mold spores in the air. These spores become airborne and start settling on other cigars. ClensAir’s patent pending 6-stage air purification technology. Can help destroy these airborne spores and stop further spread of mold. ClensAir™ utilizes latest UV and photocatalytic disinfecting technology combined with advance media filtration to eliminate 99.98% airborne mold.

Aguatronics™ cigar storage ClensAir™

Retail/Lounge

Humidity control is essential for maintaining cigars.
Aguair's Aguasonic™ system allows you precisely control humidity levels insider your humidor rooms.

Cigars are hygroscopic, and they can quickly absorb or lose humidity based on the moisture content of its surroundings. Retail cigar must be stored in temperature and humidity-controlled humidors. Humidors are required to maintain relative humidity of approximately 68-74% for optimal cigar flavors to evolve. This level of humidity also supports an even burning of the cigar.

Aguair’s Aguasonic™ system is designed to maintain the preferred set humidity levels without wetness. Its equipped with state-of-art ultrasonic nozzles that create fine 6-10 micron fog on demand. Without the use of storage vessels that could become contaminated over time and are the root cause of mold development in most humidors. This is an ideal solution for a small to large walk-in humidor owner to maintain the ingrate and quality of cigar without the sacrificing consumer’s health.

Additional areas of concern for any cigar lounge is controlling the odor emitted by cigars and maintain clean customer friendly environment. ClensAir™ helps control some of the overwhelming cigar odor and also helps reduce airborne bacteria, pathogen and mold that are within the air. In a high traffic walk-in humidors pathogens’ and mold can easily colonize on the cigars and cause the cigar to have mold spotting or discoloration. Especially in the highly humid environment like humidors. ClensAir™ can drastically reduce the chances of mold colonization which helps with cigar spoilage and improves the bottom line.

Aguasonic™ cigar retail ClensAir™
clensair for cigars
About Aguair

Aguair’s patented products have applications in a variety of industries, including agriculture, textile, paper, healthcare, and laboratories. Through industry certifications and accreditations, Aguair ensures that its products provide the utmost safety and efficiency for its customers.

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