Hi ! I am writing from Italy, this is how I process my tobacco leaves
Casing of tobacco leaves (Marco's method)
To case 100 grams of leaves:
Add 3 teaspoons of regular sugar to 100 ml of demineralized water and bring to a boil for 1 minute.
Then, let the mixture cool to 70–80°C.
At this point, add 3 teaspoons of white wine vinegar—specifically, vinegar made from organic wine fermented using a "mother" culture.
Stir briefly and let it sit for 5 minutes, then bring the entire mixture (water, sugar, and vinegar) back to a boil; this 100 ml solution must be used immediately and not stored.
Meanwhile, the tobacco leaves—de-stemmed and cut into strips—should be steamed (using a steamer, a german Bimby, or, if nothing else is available, by placing them in a sieve over a pot of boiling water). As soon as they warm up, spray them with the aforementioned water-sugar-vinegar solution (ensure the liquid has cooled to 40°C first) while mixing continuously by hand (wear gloves!).
After mixing for fifteen minutes, seal the leaves in an airtight jar (such as a Bormioli jar) for 2 days. Then, return them to the steamer and steam for another fifteen minutes. Without delay, while still hot, place the tobacco in a press; increase the pressure daily to expel the liquid. Every 2–3 days, open the press, remove the plug, and drain away the thick liquid that would not otherwise flow out on its own.
I continue pressing until I obtain a dry plug; this generally takes at least ten days. Remove the resulting plug; if the moisture level is high, wrap it in brown paper for a couple of days, then decide whether to store it in a glass jar or—preferably—vacuum-seal it for at least two months.
I am not fond of flavored tobaccos; therefore, I have so far worked with flue-cured Virginia leaves, without any flavor, processed according to the formula described above. What surprised me is that the resulting plug is highly aromatic, with a lingering scent of orange and plum.
Any comments would be appreciated