Jim this is the most detailed posting I have ever seen on the topic - originally posted by hfearly and included in the second link I provided.
My apologies for any redundancy here but I have never seen a further breakdown on the tobacco varietals beyond this description (such as where the bright Virginias originate).
Also, a quick question for you - do you think the topping/casing used today is the same (or similar) as the original?
1lb Three Nuns (Pre WW2-1971 recipe)
----------------------------
P1 15% Imported Perique (Louisiana)
P2 7% Manufactured Perique
P3 31% Filler (Burley)
P4 47% Wrapper (Bright Virginias)
Casing (F14) for the Production of Manufactured Perique P2
(23.5 lbs casing to 100 lbs of dry strips ob tobacco)
------------------------------------------------------
1.5 lbs BICARA (Rep Ref. 13A)
7.0 lbs MOLON (Rep Ref. 1A)
10.0 lbs CELANDO (Rep Ref. 5A)
5.0 lbs Water
Casing (M4) for the Treatment of Filler P3
(5.25 lbs casing to 100 lbs of dry strips of tobacco)
------------------------------------------------------
4.0 ozs CELANDO (Rep Ref. 5A)
5.0 lbs Water
Flavoring (215) for the Treatment of Imported Perique P1
(1.0 lbs of flvaoring per 100 lbs of wet tobacco leaf weight)
------------------------------------------------------
1.0 lbs BUTITE (U108)
Flavoring (208) for the Treatment of Manufactured Perique P2 and Filler P3
(5.25 floz per 100 lbs of whole blend)
------------------------------------------------------
0.25 floz of HALTRONER (Rep Ref. B3.1)
0.25 pint of BUTITE (U108)
50% of Flavoring 208 applied to Filler
50% of Flavoring 208 applied to Manufactured Perique
NOTE: Wrapper P4 leaves are unflavored
Decoding of Ingredients
------------------------------------------------------
1A "MOLON" = Reducing Sugars, Good quality invert sugar
5A "CELANDO" = Humectants, Glycerine
13A "BICARA" = Biding Agents, Gum arabic
B3.1 "HALTRONER" = Spices, Aniseed, Anethole
U108 "BUTITE" = Flavors, Demerara Rum, 40o O.P.
Manufacturing Notes
------------------------------------------------------
The Perique is imported in strip form in a manufactured state, having already
been processed in North America, where it's grown. All that has to be done is
to open up and separate the strips and to apply flavour by "spray in bed" form.
For this, the leaf is taken from the trollies and spread in layers in a bed on
a tiled floor. A previously measured amount of spray and water is sprayed on
each layer as the bed is made up layer by layer. This ensures even flavoring
throughout the bed. The flavored leaf is then picked up from the bed into
trollies that are covered with a stout canvas sheet and allowed to rest for at
least 24 hours. This allows the flavoring and moisture to permeate and even out
throughout the trolley contents (process known as "bulking"). The flavoured
Perique strips are then picked up into trollies and held until the filler and
wrapper portions are ready.
The filler grades are taken and by being passed through a conditioning machine
are pliable and capable of being handled so that all stems can be removed. After
stem removal, the filler strips are again passed through a conditioning machine
that gently warms them and makes them receptive to the flavour, which is applied
by sprays in a rotating cylinder through which the warmed strips are passed. The
flavored filler strips are discharged into trollies and bulked for 43 hours.
The wrapper leaf is selected by size of leaf, brightness of appearance, freedom
form blemishes, tears and breaks. The especially selected leaves are then
passed through a rotating cylinder fitter with water sprays and brought into a
suitable condition for stemming, which is done very thoroughly by hand. It is
then placed into trollies to await the amalgamation process where the wrapper
is combined with the Perique and the filler mix in a spinning process.
The spinner takes strips of Perique and rolls them into a very tight roll or
"string", keeping the diameter continuous by adding more Perique strips as
needed, as long as the rolling continues. The central core "string" is wrapped
with the filler strips and then wrapper in the wrapper leaves. The leading end
of the roll is then fed into a set of motor driven rollers which reduce the
hand rolled spun down to 7/16s of an inch in diameter, and at the same time
causing the tobacco to roll to turn on its axis and pass into the machine. This
turning and traversing action facilitates the spinning as the operator
continues to maintain the feed of Perique filler and wrapper by overlapping
further supplies as the ends pass through the spin machine.
The spun tobacco, known as "rope", is automatically wound onto reels or
bobbins, each holding 300 feet of an approximate weight of 25 lbs. These reels
are set aside and held for 48 hours. The rope is then unwound, cut into 4/5'
lengths that are take to a cutting machine and cut at 22 cuts to 1 inch each.
The cut tobacco is carefully placed into trays without damaging the flakes and
the trays are placed in a trolley and into a drying oven (265 F, 9 minutes).
The flakes are dried to the final desired packing moisture content (19/20%). On
removal from the drying oven, the flakes are allowed to cool and then (in the
same trays) is placed into a store and held for 24 hours, such that the
moisture is allowed to even out before the finished product is sent to the
packaging room.