Tag: Zimbabwe2023

  • The Man Behind the Plan

    The Man Behind the Plan

    Anxious Jongwe Masuka
    (Photo: Taco Tuinstra)

    Zimbabwe’s minister of Agriculture, Anxious Jongwe Masuka, explains how the country will build a $5 billion tobacco industry by 2025.

    By Taco Tuinstra

    Following the resignation of Zimbabwe’s longtime president, Robert Mugabe, in late 2017, the new government invited private citizens to provide ideas on how to improve agriculture. Drawing on his extensive background in agriculture, policy and strategy, Anxious Jongwe Masuka wrote a letter in which he detailed the steps that he believed would help the nation achieve a prosperous, sustainable and competitive agricultural sector.

    One of the issues he mentioned was tobacco, the country’s most important agricultural export by a wide margin. Zimbabwe has the potential to generate and retain much more value from its tobacco industry than it is getting now, Masuka argued in his missive, unaware that he would soon be put in charge of the sector.

    “Then, when I was appointed a minister, President Emmerson Mnangagwa handed me back my letter and said, ‘I fully agree with what you have written here, and now please go ahead and implement it,’” recalls Masuka.

    Tobacco Reporter caught up with Masuka at the Ministry of Agriculture in Harare to discuss the details of what is now known as the Tobacco Value Chain Transformation Plan.

    Tobacco Reporter: Please briefly sketch the economic significance of tobacco to Zimbabwe. How much of the value created is retained domestically, and why does it fall short of its potential?

    Anxious Jongwe Masuka: The context of the tobacco industry in Zimbabwe is exciting, since the first tobaccos were grown by missionary priests and presented at a show in 1895. Tobacco is one of [the] great successes for the country. By 1998, 1,500 large-scale white farmers produced a record 239 million kg. At the time, only a handful of small-scale Black farmers, less than 1,000, produced the crop. Following the land reform program from 2000 onward, the demography has dramatically shifted. A new record 260 million kg was produced in the 2019/2020 season, predominantly by smallholder farmers who constitute over 85 percent of the growers.

    The tobacco crop annually supports up to 160,000 households, accounts for more than 50 percent of agricultural exports and contributes 25 percent to agriculture GDP.

    Tobacco production is now a catalyst for accelerated rural development. Tobacco is grown predominantly by smallholder farmers, who constitute 85 percent of producers. Tobacco supports, directly and indirectly, 10 percent of Zimbabwe’s population (1.5 million).

    Some 98 percent of tobacco is exported in a semi-processed form. However, according to the Reserve Bank of Zimbabwe, only 12.5 percent of total exports is the net benefit after payment of external loan obligations by tobacco merchants.

    Zimbabwe produces 6 percent of the world’s tobacco. The global tobacco market is estimated at US$850 billion, and 6 percent of the value translates to $51 billion of the global market value of tobacco. In 2020, Zimbabwe produced and exported over 200 million kg of tobacco worth only $991 million, so clearly there is scope for massive value retention in the country.

    This is the basis for the Tobacco Transformation Plan, an idea I floated to the president in 2018 when I was still in the private sector and before being appointed minister in August 2020.

    What are the Tobacco Transformation Plan’s main objectives?

    From the mentioned statistics, it is clear that the industry must transform for value preservation and for sustainability. The Tobacco Value Chain Transformation Plan seeks to increase tobacco production to 300 million kg by 2025 and transform the value chain into a $5 billion industry through exports of tobacco value-added products. The broad objectives of the plan are to accelerate localization of tobacco funding; increase tobacco productivity and production from 210 million kg to 300 million kg; increase production of alternative crops and increase their contribution to farmers’ incomes; increase the level of tobacco value addition and beneficiation into cut rag and cigarettes; and ensure sustainability and traceability in the production of the crop.

    Why is such a large share of cultivation currently funded by contractors? And how does the Tobacco Transformation Plan seek to remedy this situation?

    Collateral, title deed-based financing collapsed in 2000, when all agricultural land became state land. By 2004, tobacco production had plummeted to 48 million kg from a high of 239 million kg. A dual marketing system was then introduced by government—a contract system was allowed, operating alongside the established auction system. Over the years, the contract system was refined to provide agronomic and farm infrastructure and equipment support in addition to inputs and working capital. Resultantly, and cumulatively, over 95 percent of production is currently funded through contract farming. This contract production financing model of tobacco requires that tobacco be prefinanced by offshore funding.

    Local lending by local financial institutions for farming purposes is limited, particularly for small-scale farmers who do not meet the collateral requirements following the collapse of title-based lending in 2000.

    The localization plan will involve government availing $60 million as seed finance to establish a revolving facility. The plan will operate alongside contract production of the crop. This will anchor the growth to 300 million kg.

    How do you view the role of tobacco buyers in the future? Will they still be funding tobacco cultivation after the Tobacco Transformation Plan has been carried out?

    Zimbabwe envisages growing the tobacco industry to a 300 million kg crop by 2025—an additional 90 million kg from the current average production of 210 million kg—so there is room for both contractors and local financing. The government is not replacing anyone in the current system, especially contractors and buyers. In fact, the exact opposite—we require more contractors and more localization of financing. We envisage that contractors can operate in both systems, whether the source of financing is offshore or is local, a contractor will be required alongside some direct lending to farmers.

    According to some economists, one of the reasons smallholder tobacco growers have struggled to access funding in the past was lack of titles to their lands. What is the current situation in terms of property rights? Does the Tobacco Transformation Plan deal with this issue?

    Those economists are misguided. Tobacco production has reached an all-time high in the current tenure system, post-land reform. All agricultural land is vested in the state, and for the right reasons, following the land reform program. Farmers got offer letters, and now securitized A1 and A2 permits and thereafter 99-year leases. It is in this context that tobacco production has grown through strong value chain or contract-growing support.

    Government is currently seized with the legal reviews to make permits and leases more attractive to financiers, so issues of collateralization, transferability and valorization are being discussed.

    It is also important, for emphasis, to highlight that the Tobacco Transformation Plan is an agronomic plan, not a land reform plan.

    Are you confident that Zimbabwe can sell a 300 million kg crop even as global cigarette consumption stagnates?

    Zimbabwe will achieve 300 million kg of production by 2025 through increased yields and reduced post-harvest losses. Zimbabwe produces flavor-style tobacco, currently marketed to 60 countries. This style of tobacco will continue to be in demand for the foreseeable future in these countries and beyond. We are also exploring new markets to replace lost markets. Tobacco smoking is by choice, and we think many will continue to choose to smoke Zimbabwean tobacco.

    Tobacco cultivation has environmental impacts, such as deforestation. What measures are in place to protect the environment as the tobacco industry expands?

    The targeted increase in volume to 300 million kg is not from area increase but from post-harvest loss reduction and yield increase. There is, therefore, no envisaged additional deforestation from the increased production. However, the government has created a law for tobacco farmers, so there is an afforestation levy administered by the Ministry of Environment, Climate, Tourism and Hospitality to reverse deforestation caused by the tobacco sector. The industry has a sustainable forestry association, which plants tens of thousands of eucalyptus trees annually.

    Alongside this, research and development has also led to more efficient curing systems, reducing wood and coal usage from 10 kg [of tobacco] to 1 kg [of] tobacco and 6 kg [of tobacco] to 1 kg [of] tobacco, respectively, to almost 1 to 1 for coal to tobacco in current continuous curing systems. Biofuels are also promising fuel alternatives to curtail deforestation.

    All contractors have now signed the sustainability code, and traceability has been heightened to ensure farmers use alternative curing fuel. Growers are also encouraged to plant 1 hectare of trees for every 7 hectares of tobacco, and seedlings are readily available.

    This cocktail of measures will reduce the industry’s environmental footprint.

    Please comment on the Tobacco Transformation Plan’s goal to promote alternative crops. What crops are you targeting, and how do they compare to tobacco in terms of earnings for the farmers and economic contributions to the country?

    Tobacco is already grown in rotation with various crops, for example, maize, and there is also livestock grazing on rotation grass. We need to enhance these and look for alternative crops, for example, industrial hemp and cannabis. The objective is to complement tobacco, not to replace it.

    In 2018, Zimbabwe legalized cannabis for medical and industrial use, with some predicting earnings on par with those of gold. How has the cannabis industry developed since 2018? What have been the major lessons of Zimbabwe’s experience with this crop to date, and what are your expectations for its future?

    Zimbabwe has just legalized the production of cannabis and has issued licenses to 60 growing units. This industry is at a developmental stage, and we expect rapid growth.

     

    The Tobacco Transformation Plan seeks the beneficiation of tobacco by encouraging value-added production. What progress has been made in this area to date? Please comment on the reports about local cigarette factories planned by Cut Rag Processors and Iranian Tobacco Co.

    The environment for investment has seen much improvement, and we expect investors to take advantage of this, including Cut Rag Processors, the Iranians and many others.

    What do you consider to be the greatest challenges to achieving the objectives of the Tobacco Transformation Plan? And how are you addressing those challenges?

    By far the greatest threat is from the World Health Organization Framework Convention on Tobacco Control, which seeks to eliminate tobacco smoking. This will have tragic consequences for tobacco-dependent African countries such as Malawi, Tanzania, Zambia, Mozambique and Zimbabwe.

    Then there are issues of adherence to sustainability and traceability and ensuring growers’ viability.

    More discerning markets want their tobacco to be produced ethically and sustainably. These are legitimate concerns. We are taking this on board and going to every length to show we are producing this tobacco in a sustainable manner, eliminating child labor, traceability, harmful substances, etc.

    Ultimately, growth in this industry will depend on grower viability. Due to the war between Russia and Ukraine—two major sources of raw materials for fertilizer production—and disruptions to the global supply chain, among other factors, the cost of production for tobacco [has] increased by 30 [percent] to 40 percent. Without a corresponding increase in the price, this means that farmers are squeezed and will therefore have to produce the crop more efficiently.

    We must highlight also that success of the Tobacco Transformation Plan depends on a whole-of-industry approach. The government has created a tobacco working group involving all stakeholders. Every quarter, representatives of tobacco growers, labor unions, buyers, bankers and regulators meet to discuss progress of the Tobacco Transformation Plan, and we look forward to accelerating its implementation.

    Have the various stakeholders generally been receptive to the Tobacco Transformation Plan?

    They have been extremely receptive. The Tobacco Transformation Plan was long overdue.

    Taco Tuinstra is Tobacco Reporter’s editorial director.Based in Raleigh, North Carolina, USA, he coordinates the work of staff writers and contributors.On his watch, Tobacco Reporter has won several awards for editorial excellence.Since joining the magazine in 1997, Taco has visited more than 75 countries to meet industry representatives in their markets and to report tobacco news firsthand.
  • The Scientific Approach

    The Scientific Approach

    The Tobacco Research Board in Harare | Photos: Taco Tuinstra

    Boosting Production Through Innovation

    By Taco Tuinstra

    The tobacco transformation plan aims to boost production without expanding the farmer base or laying claim to significantly more farmland (see interview with Minister of Agriculture Anxious Masuka). To help the government achieve its objectives, the Tobacco Research Board (Kutsaga) (TRB) is developing improved seed varieties, innovating to reduce post-harvest losses and creating education programs for tobacco growers.

    According to TRB CEO Frank Magama, the key to sustainable growth is improving yields. Just recently, the TRB released four new flue-cured tobacco varieties developed for marginal growing areas in the south of Zimbabwe, which is dryer than the rest of the country. With traditional tobacco varieties, farmers in that region have been getting yields of about 1,100 per hectare. Magama hopes the new varieties will boost that number to 2,500 kg per hectare.

    The varieties have been issued on a so-called limited-release protocol. “We allow 20 farmers to grow one hectare each so we can get more data and learn whether the new varieties are suitable,” says Magama. If, in consultation with the growers, the breeders are satisfied with the results, they will move to the next stage of the trials. In the second season of evaluation, the TRB will distribute seed for these varieties among a larger number of farmers for further testing. In addition, tobacco merchants will test-smoke cigarettes manufactured with tobacco from the new varieties to make sure they deliver the desired flavor. Altogether it will take between three years and four years from the start of the trials until the new varieties will be available to all growers in the targeted areas.

    Recently, the TRB released four new flue-cured tobacco varieties developed for marginal growing areas in the south of Zimbabwe, which is dryer than the rest of the country.

    Reducing Losses

    The TRB is also looking at reducing post-harvest losses. According to Magama, smallholder farmers may lose up to 50 percent of their crops due to inadequate handling. “If you look in the field, it may be a 3 ton crop,” he says. “But what goes to auction is perhaps 1.5 tons.”

    The problem starts before the tobacco even leaves the farm. After curing, the leaf is very brittle, and to prevent breakage while moving the leaf from the curing barn to the shed, it must be conditioned. Ideally, this is done with a misting system, but this requires piping and electricity, which are often unavailable in the rural areas. So small-scale farmers may just use boiling water, which doesn’t generate the proper mist. As a result, a needlessly high share of good tobacco ends up as scrap that may sell for perhaps $0.10 per kg—or, more likely, end up as compost.

    “It’s an issue of infrastructure,” says Magama. In partnership with a tobacco equipment manufacturing company, the TRB evaluated a portable firewood steam boiler for tobacco conditioning. This portable unit can be moved from barn to barn and also to grading facilities with ease and without a need for extension pipes. “If we solve that aspects of losses, we can significantly boost yields.”

    We hope that eventually hemp can be grown on tobacco farms, either as a rotation crop with tobacco or eventually as an alternative to tobacco.

    Frank Magama, CEO, Tobacco Research Board

    At the same time, Kutsaga is working to reduce the amount of wood required for tobacco curing and other farm activities. The shift from commercial growing (which uses mostly coal as a curing fuel) to smallholder production has put considerable pressure on Zimbabwe’s forest cover. Innovations such as the rocket barn and Kutsaga’s counter-current barn use up to 50 percent less wood than conventional barns. And while the rocket barn is comparatively expensive, Magama believes farmers can significantly reduce its cost through materials substitution, by making their own bricks, for example.

    The TRB has also been distributing eucalyptus tree seedlings to farmers but with mixed success. Tobacco growers are not always keen to plant trees on land that could be used for other crops. So the board is also working with schools in rural areas. “We donate seedlings and presented it as an educational and commercial opportunity,” says Magama. Tending to the trees is light work—you will need to protect them against termites, for example—and within three years to four years, the schools will have timber that they can sell to tobacco farmers and other users. “The initiative with the schools has gotten a lot more traction than working directly with tobacco growers,” says Magama.

    The TRB is building a model farm at its Kutsaga Station to teach tobacco growers good agricultural practices

    Model Farm

    Another way to improve tobacco yields is through education and training. This is extensively done through what Kutsaga terms tobacco improved productivity sites (TIPS), where training is done on farms in selected tobacco-growing areas. Farmers from the area are provided with all the necessary inputs and then trained year-round on these sites. The TRB is currently also building a 6 ha model farm at its Kutsaga Station to teach tobacco growers good agricultural practices: How do you properly rotate tobacco and food crops, and what else can you cultivate on your farm? “We are also doing this to prepare growers for a future with less smoking,” says Magama. Upon completion of construction of the facility, the TRB will select a grower to live and work full time on the farm with his family. Supported by the best agronomic advice, this farmer will then become a visual model for other growers to emulate.

    Meanwhile, the TRB itself is adjusting to a changing market with declining cigarette consumption. Following the legalization of industrial hemp and cannabis for medicinal use in Zimbabwe in 2019, the board has set up three stations for hemp research. According to Magama, it would be relatively easy for tobacco farmers to get into hemp. “We hope that eventually hemp can be grown on tobacco farms, either as a rotation crop with tobacco or eventually as an alternative to tobacco,” he says. Kutsaga is also investigating crops such as stevia and chia.

    Looking further ahead, Magama would like the TRB to venture into biopharming, using tobacco to develop compounds of value, such as pharmaceuticals or vaccines. He hopes some of the board’s current innovations will help generate money to fund the modern labs required for such endeavors. For the time being, it remains a dream only. If it becomes reality, however, it will provide an unrivaled boost to Zimbabwe’s effort to extract more value from its tobacco business.

    Taco Tuinstra is Tobacco Reporter’s editorial director.Based in Raleigh, North Carolina, USA, he coordinates the work of staff writers and contributors.On his watch, Tobacco Reporter has won several awards for editorial excellence.Since joining the magazine in 1997, Taco has visited more than 75 countries to meet industry representatives in their markets and to report tobacco news firsthand.
  • The Trade’s Perceptive

    The Trade’s Perceptive

    The Trade’s Perspective: Leaf Merchants Urge Sustainable Growth

    By Taco Tuinstra

    Stakeholders in Zimbabwe’s tobacco business have generally been receptive to the Tobacco Value Chain Transformation Plan (TVCTP), which among other things aims to boost leaf production and move up the value chain (see interview with Minister of Agriculture Anxious Masuka). “The plan has some sound fundamentals,” says Mark Mason, managing director of Zimbabwe Leaf Tobacco Co., a subsidiary of Universal. “It sensibly talks about vertical growth—boosting tobacco production by improving yields and cutting losses rather than expanding hectarage or increasing the number of farmers. Those are admirable objectives.”

    At the same time, the industry is counseling caution and realistic expectations. In recent years, some entrepreneurs have moved beyond Zimbabwe’s mainstay of flue-cured Virginia (FCV) production. Several companies, including Mosi Oa Tunya Cigars (see “The Smoke that Thunders,” Tobacco Reporter, June 2021), are now manufacturing cigars with locally grown tobacco. Cavendish Lloyd is experimenting with low-nicotine FCV for shisha products (see “Great Expectations,” Tobacco Reporter, May 2022). There are also several companies producing cigarettes for the local market. In October 2022, Cut Rag Processors announced it would build an $80 million cigarette factory in Harare. Iranian Tobacco Co. has expressed interest as well, though the discussions are only at an exploratory stage.

    The plan sensibly talks about vertical growth—boosting tobacco production by improving yields and cutting losses rather than expanding hectarage or increasing the number of farmers.

    Mark Mason, magaging director, Zimbabwe Leaf Tobacco

    But while BAT and some of its smaller competitors have been happy to manufacture limited amounts of cigarettes in Zimbabwe, it’s doubtful that big players such as Philip Morris International and Japan Tobacco International will build factories in Zimbabwe. Serving global markets and headquartered in Western capitals, the multinationals are guided by purely commercial considerations and generally seek to establish their manufacturing operations in countries with smooth roads, reliable power and business-friendly legislation—areas in which Zimbabwe faces strong competition. For these and other reasons, significant local cigarette production for exports by the majors may remain a bit “pie in the sky,” according to one tobacco veteran.

    The merchants, in turn, are content with their current position in the value chain, which ends after the transformation of green leaf into unmanufactured tobacco. Currently, there are three tobacco processing factories in Harare—ZLT, Mashonaland Tobacco Co. (MTC) and Tobacco Processors Zimbabwe, which is managed by Northern Tobacco. “We have no investments beyond processing,” says Rob Holmes, executive officer of the Tobacco Leaf Exporters Association of Zimbabwe (TLEAZ), which represents nine leaf dealers with lamina exports of at least 1 million kg each and accounts for 85 percent of the contracted crop. According to Holmes, moving into cigarette manufacturing would put the merchants in direct competition with their customers—a situation they are obviously keen to avoid. “So, monetary-wise, the value addition described in the plan would take place very much after our stage of the chain,” he says.

    Merchants warn that, in the current market, Zimbabwe may struggle to sell 300 miillion kg.
    (Photos: Taco Tuinstra)

    Contracting with tens of thousands of farmers, the merchants are better positioned to help grow the crop. But here, too, they are urging caution. “In the current world market, we would struggle to sell 300 million kg,” says Holmes. “There has been a bit of an increase in the demand for our leaf from China [which purchases 40 percent of Zimbabwean volumes] but not to the extent that you can soak that up.” According to Holmes, the styles that normally go into China are unique to that market and relatively expensive. “Where do you find customers for the excess volumes of those styles?” he asks.

    The demand for Zimbabwe’s prized flavor grade tobacco, too, is limited. “International customers require only so much of that style,” says Holmes. “Otherwise, you’d be getting into more filler grade tobaccos, and then you are competing purely on price whilst you’ve got cost-of-production issues.” Supply chain disruptions in the wake of Covid and the war in Ukraine have driven up the cost of inputs such as fertilizer and fuel considerably during the most recent growing season. In addition to such global factors, the Zimbabwean industry has had to cope with local cost pressures this season, such as erratic supplies of electricity and exchange rate rules that force businesses to buy Zimbabwean dollars at official rates while paying significantly higher parallel-market rates for their supplies.

    Leaf merchants also want to make sure the targeted volume increases are achieved sustainably.

    Leaf merchants also want to make sure the tobacco transformation targeted volume increases are achieved sustainably. “We support the government’s goals, but we need to make sure that they are aligned with customer expectations,” says Alex Tait, managing director of MTC, a subsidiary of Alliance One International. Leading cigarette manufacturers these days expect their tobacco to be produced in line with strict environmental, social and governance (ESG) criteria, which means keeping close track of agricultural practices, labor conditions and environmental impacts, among other issues.

    The shift from commercial tobacco production to smallholder cultivation has put tremendous pressure on Zimbabwe’s forests. Before the land reforms at the start of the century, the bulk of Zimbabwe’s crop was produced by about 1,500 commercial farmers, who at their peak in the late 1990s brought some 239 million kg to market. Today, similar volumes are cultivated by nearly 160,000 growers, the vast majority (85 percent) of them smallholder farmers. But whereas the commercial farmers use primarily coal to cure their tobacco, the smallholders rely mostly on wood, creating a voracious demand for timber.

    In a presentation to industry stakeholders, including the ministry of agriculture, which drew up the TVCTP, the tobacco industry stressed the importance of meeting ESG objectives, noting that there is no point in growing additional volumes if you cannot sell them. Failing to fulfill ESG requirements, the industry cautioned, will prompt customers to source their leaf elsewhere, leaving the Zimbabwean tobacco grower impoverished.

    The trade insists the tobacco value chain transformation plan’s objectives must be consistent with customers’ ESG expectations.

    To ensure sustainable growth, tobacco merchants have been developing renewable sources of curing fuel by establishing woodlots and providing farmers with seedlings. Financed by a voluntary leaf dealer contribution, the industry’s Sustainable Afforestation Association has been planting trees since 2013 and is preparing for its first harvest next season. Despite its considerable efforts, the organization still does not have enough renewable wood to cure the current crop, let alone the additional volumes described in the transformation plan.

    One of the constraints, according to industry representatives, is access to land close to the tobacco growing areas, which has been mostly in state hands since the land reform program. The prime lands for timber production are in the east of the country, which means added cost for transportation. The government meanwhile collects levies from growers to invest in reforestation, although critics say it is unclear how the money is being invested.

    In addition to increasing its supply of sustainable wood, the industry is working to reduce its consumption by helping farmers adopt more efficient curing systems. Innovative designs, such as the rocket barn, allow growers to reduce their wood consumption by up to 50 percent, although costs are a hurdle. At $2,000 per unit, the rocket barn is out of reach for the typical smallholder tobacco grower. The industry is also researching alternative energy sources, such as gas, biomass and briquettes, to curtail deforestation.

    The opportunity for Zimbabwe to extract more value from its tobacco industry begins and ends with the ability of the farmer to make a living income.

    Meanwhile, the trade is contributing to vertical growth by helping small-scale growers increase their yields. Benefiting from tailored inputs and agronomic extension services, contracted growers have in recent years increased their productivity to an average of 1,700 kg per hectare, a figure the industry hopes to drive up to 2,200 kg per hectare in the future. The national average, which includes independent growers selling at auction, is estimated at only 800 kg per hectare, however, suggesting considerable opportunity for growth.

    “In well-managed contract schemes, with the right service levels, the right inputs and the right advice, you can get very good yields,” says Mason. “That needs to roll out throughout the industry. There is definitely opportunity for the newer contractors or the smaller contractors to push through better programs.”

    Zimbabwe’s regulator, the Tobacco Industry and Marketing Board, is in the process of implementing a minimum input standards package recommended by the TLEAZ—not only to increase the crop size and benefit the national economy but also to improve the profitability and livelihoods of individual growers. As all stakeholders interviewed for this article acknowledged, the latter will be crucial for the success of the tobacco transformation plan. After all, the opportunity for Zimbabwe to extract more value from its tobacco industry begins and ends with the ability of the farmer to make a living income.

    Taco Tuinstra is Tobacco Reporter’s editorial director.Based in Raleigh, North Carolina, USA, he coordinates the work of staff writers and contributors.On his watch, Tobacco Reporter has won several awards for editorial excellence.Since joining the magazine in 1997, Taco has visited more than 75 countries to meet industry representatives in their markets and to report tobacco news firsthand.
  • ‘Not Really a Gamble’

    ‘Not Really a Gamble’

    Leaf Dealers Look Forward to Receiving a Good Quality Crop

    By Taco Tuinstra

    While the Tobacco Industry and Marketing Board had yet to release official figures at the time of Tobacco Reporter’s visit to Zimbabwe in early April, traders were expecting farmers to bring 230 million kg to market in the 2023 selling season. That compares with 212 million kg in 2022, which in turn was up from the two years prior.

    The increase was due in part to good climate conditions despite the influence of an El Nino. The periodically recurring atmospheric phenomenon typically results in wetter than normal conditions in southern Africa from December to February. But in the event, it wasn’t all that wet.

    “The crop was planted on time, and weather patterns were generally favorable,” says Alex Tait, managing director of Mashonaland Tobacco Co., a subsidiary of Alliance One International. As is the case throughout Africa, curing space proved a constraint in Zimbabwe this year. Fast ripening in some areas created some quality challenges toward the tail-end of the season, but nothing pointing to disaster. “It was a normal season,” says Tait.

    Traders at the Tobacco Sales Floors in Harare
    (Photos and video: Taco Tuinstra)

    Zimbabwean volumes have largely recovered from the disruption that followed the government’s land reform program, which shifted the emphasis from commercial growing to small-scale farming during the 2000s and at one point saw the crop plummet to 50 million kg. 

    The quality produced by smallholders has also been steadily improving, thanks in part to contractors’ extensive support of their growers. This season, overall quality is fair to good, according to Mark Mason, managing director of Zimbabwe Leaf Tobacco Co. (ZLT), which is associated with Universal. “Despite the majority being smallholder, the Zimbabwean tobacco grower is a good farmer,” he says. “If they are serviced well, they produce a very acceptable crop.” In fact, Zimbabwe’s combination of climate, soils and skills means tobacco merchants have come to expect a decent crop, observes Mason. “It’s not really a gamble for us—unless the weather gets very poor,” he says.

    Volumes this year were further boosted by good pricing in the 2022 marketing season, which spurred growers’ interest. What’s more, the payment modalities have recently improved, with growers receiving a higher share of their earnings in U.S. dollars as opposed to the less valuable local currency.

    Meanwhile, pricing has become quite competitive in the contracting arena. “We have a situation in  which more contractors are chasing fewer growers,” says Mason. “If you want to expand in this market, you have to coax a grower to come and join you. You have to argue your case, explain why he should leave X and join Y. The pricing this year will take into account some of those costs.”

    Mason expects an increase of about 9 percent in the average per-kilo tobacco price this year, also as a result of the rising cost of production. The price of fertilizer, in particular, spiked in the run-up to this growing season, mostly due to the war in Ukraine, which traditionally supplied many of the raw materials needed for fertilizer production.

    At the same time, erratic power supply in Zimbabwe forced commercial growers, who need electricity to operate their curing barns, to use diesel generators, which is more expensive than pulling power from the grid. The shortages were driven by low water levels in Lake Kariba, which houses a major hydroelectric power dam and is crucial to regional energy security, and maintenance at the Hwange power station. Power supply will likely remain a concern going forward, but Tait is cautiously optimistic that recent rains in the catchment areas along with progress at Hwange will help ease the shortages next season.

    Despite the anticipated price hikes, exporters expect demand for Zimbabwean leaf to be firm again this season. Tait believes part of that is due to the lingering impact of Covid. “People thought that smoking would go down during the pandemic, but it actually went up,” he says. So the global crop size dipped over the past two years even as cigarette consumption increased. “Of course, there is a question about how long that situation will last,” says Tait. “Zimbabwe’s crop has gone up, as has Brazil’s, so we may see demand level out next year.”

    The switch to smallholder growing has radically changed the leaf merchants’ business models. “In the past you used to go and buy what you liked and sell it; now you get a crop throw and you have to figure out how to market that effectively,” says Mason. With contracting accounting for 90 percent of Zimbabwean volumes, dealers these days operate extensive agronomic departments. ZLT alone has well over 100 on-the-ground field staff along with countless cars and motorbikes to service its growers in the countryside. The merchants have also (reluctantly) assumed the role of financiers because the new growers have no collateral with which to secure bank loans. Post land reform, all agricultural land belongs to the state in Zimbabwe.

    While dealing directly with thousands of smallholders is a herculean logistical exercise with a huge impact on cost, the shift has also had an unexpected advantage for the tobacco merchants. “In a way, it’s what has allowed us to tick the right boxes because now everything is traceable,” says Tait. “The manner in which ESG [environmental, social and governance] requirements have evolved in recent years is working out for us because we are right down to the farm level to make sure that what the grower is doing is compliant.”

    Taco Tuinstra is Tobacco Reporter’s editorial director.Based in Raleigh, North Carolina, USA, he coordinates the work of staff writers and contributors.On his watch, Tobacco Reporter has won several awards for editorial excellence.Since joining the magazine in 1997, Taco has visited more than 75 countries to meet industry representatives in their markets and to report tobacco news firsthand.
  • Iranian Tobacco Co. to Build in Zimbabwe

    Iranian Tobacco Co. to Build in Zimbabwe

    Photo: www.akolosov.art

    The Iranian Tobacco Co. (ITC) will build a cigarette factory in Zimbabwe, reports Press TV.

    According to local media reports, ITC CEO Mohammad Sheikhan and Zimbabwe’s agriculture minister, Anxious Jongwe Masuka, signed an agreement in Harare on Jan. 26.

    The facility will manufacture ITC’s Bahman brand using Zimbabwean leaf tobacco. As part of the agreement, Zimbabwe will also supply tobacco for cigarette manufacturing in Iran or for re-exports to Central Asia.

    Other Iranian-made cigarette brands will be exported to Zimbabwe under the deal.

    Iran’s tobacco sector has grown in recent years amid lower imports of international brands and increasing demand for local products.

    The boom has enabled the ITC to revive idle plants and to start exporting to several countries in West and Central Asia.

    The company’s planned cigarette factory dovetails with Zimbabwe’s ambition to move up the tobacco value chain. While the country exports hundreds of millions of kg of leaf each year, most of the value is captured by the buyers who process the tobacco into consumer products.

    The country aims to generate US$5 billion from tobacco by 2025, up from US$1 billion today.

  • CRP to Build $80 million Plant in Harare

    CRP to Build $80 million Plant in Harare

    Photo: Tobacco Reporter archive

    Cut Rag Processors plans to build an $80 million cigarette factory in Harare, Zimbabwe, reports The Sunday Mail, citing sources familiar with the project.

    The company, which is one of the country’s largest exporters of cut rag and manufactures the Remington Gold cigarette brand, has already started clearing 60,000 square meters of land in the Lochinvar industrial area.

    The factory will have both a primary department for the production of cut rag and a secondary department for the manufacture of cigarettes, an unnamed source told The Sunday Mail.

    While confirming the construction of the new facility, Cut Rag Processors Managing Director Nyasha Chinhara declined to provide details, citing “finalization of confidential internal processes.”

    The project fits with Zimbabwe’s Tobacco Value Chain Transformation Plan, which aims to extract more value from the tobacco business.

    The world’s sixth largest producer of leaf tobacco, Zimbabwe currently captures only a fraction of the trade’s value. The government aims to unlock $5 billion in export revenue by 2025.

    Net foreign currency inflows from tobacco stood at $45.7 million in 2020. About 98 percent of tobacco produced in Zimbabwe is exported in green (semi-processed) form by big tobacco merchants.

    Zimbabwe has three processing facilities owned by Zimbabwe Leaf Tobacco, Tobacco Processors Zimbabwe and Mashonaland Tobacco Co.

    Cut Rag Processors was formed in February 2000 as the first independent cut rag production facility in Zimbabwe servicing both the domestic and export markets.

    The establishment of the company paved the way for the merger of BAT and Rothmans in 2000. Previously, the Competition and Tariff Commission had rejected the merger out of concern that the merged entity would create a monopoly.

    Between 2012 and 2014, Cut Rag Processors closed its cigarette line. A year later, the company decided to exit the entire tobacco business. It returned to production after its owner, Gold Leaf, sold the business to new shareholders in 2019.

    Encouraged by the government’s plan to boost Zimbabwe’s tobacco earnings, the new investor injected capital into the manufacturing business.

  • Failure to Launch

    Failure to Launch

    Photo: Aleksandr

    Zimbabwe’s attempt to diversify into cannabis is proving more challenging than some anticipated.

    By Daisy Jeremani

    Zimbabwe announced its approval for cannabis growing for medicinal and industrial use in April 2018 amid much hope for an immediate economic impact.

    Finance Minister Mthuli Ncube projected export revenues of up to usd1.2 billion in the first year of growing, processing and exporting the crop and its products. The forecast is almost at par with what gold, the southern African country’s most lucrative export, brings in—and higher than the amount it generates from tobacco, its current No. 1 agricultural export. Cannabis was, too, touted as a diversification route for tobacco growers amid declining demand for the golden leaf.

    However, experts have cautioned that Zimbabwe may not realize the benefits as rapidly as authorities initially projected. Forty-two months since the government issued the first licenses, only 15 out of the 57 companies have started work, hampered by a plethora of challenges. Chief among them: lack of financing and expertise.

    Speaking to Tobacco Reporter just after her organization, Zimbabwe Industrial Hemp Trust (ZIHT), hosted a cannabis roundtable under the theme “Unpacking the Challenges and Potential of Cannabis as a Medicine” in Harare, the capital city, on Sept. 7, 2022, Zorodzai Maroveke said a lot of work still needs to be done for the country to realize gains from the crop.

    A key proponent of legal cannabis production, Maroveke said most licensees lack guaranteed off-take agreements. An unstable market has not helped matters, she added, as prices have kept fluctuating since Zimbabwe became Africa’s second nation after Lesotho to legalize cannabis for medicinal and industrial use.

    “An unstable market has been a major challenge for investors to move forward with this project in Zimbabwe and also the issue of funding. Most banks are not willing to finance cannabis because they still don’t understand it,” said the ZIHT founder and CEO.

    Another obstacle for license holders is that they have to import expertise as this is a new frontier for the country. Recruiting the right skills is expensive. The cannabis regulatory framework, which she described as very strict, has also hampered the speed at which the industry is progressing.

    Maroveke said the cost implications of growing medicinal cannabis are high, citing the European Union’s good manufacturing practices (GMP), which force producers to set up facilities of a high standard of hygiene and security and hire well-trained personnel.

    “You will find that for a very small project, maybe even a hectare project, one would potentially pump out not less than usd1million,” said Maroveke.

    So if one is to expand, there is a need for more funding, not considering money that must be paid for the GMP compliance auditors as well as inputs, like seeds, which are not only expensive but are also imported.

    Though industrial hemp is generally cheaper to produce than medicinal cannabis, the cost depends on its type, she noted. If it is botanical, which is grain hemp for the CBD flower, one should be prepared to part with at least usd200 for a 5 ha project. The market determines the standards and quality that the farmer has to put in.

    “So if you’re going to do hemp for fiber and grain, it’s obviously going to be cheaper; you’re looking at usd3,000–usd4,000 a hectare. But Zimbabwe’s hemp and grain industry hasn’t developed to that extent, so we don’t have many activities in those particular subsectors of industrial hemp,” she said.

    Tobacco is likely to remain Zimbabwe’s No. 1 agricultural export for the foreseeable future. (Photo: Cavendish Lloyd)

    The Sept. 8 roundtable was meant to find, bridge and plug the knowledge gap not only among health professionals but also other experts along the value chain. It is against that backdrop that a top Zimbabwean pharmaceutical supplier, New Avakash International, awarded scholarships to 100 health personnel to undergo training to make them more conversant with cannabis.

    At the moment, local varieties are at the research stage. Due to the dictates of the market, buyers direct farmers toward the genetics they want, which at this stage are all imported. As a result, roundtable participants called for more investment in research and development and the development of local growing and processing expertise. As the industry tries to find its place, Maroveke said the government should support it through tax breaks and other incentives for cannabis value addition to be accelerated.

    She said Zimbabwe will only realize the gains from cannabis once production kicks off and the export markets are stable and guaranteed.

    Former Zimbabwe Tobacco Research Board (TRB) CEO Dahlia Garwe noted that the country leapt in headfirst without conducting proper market research.

    “We were supposed to look at what kind of varieties we should be growing and where exactly the material will end. We have a lot of cases where people grew cannabis, but they don’t know what to do with it,” she said.

    Garwe noted that the costs involved in setting up facilities for the processing of the herb and for a basic setup are as high as usd400,000. For a facility that is compliant with all the necessary health requirements, the costs can be about usd3 million.

    With regards to research that is underway, she said experts are looking for locally adapted germplasm, with the TRB going around the country to identify varieties adapted to the local environment. After that, they would breed local varieties and material from elsewhere to come up with varieties that are most suitable for Zimbabwe.

    “That is ongoing work. It will obviously take a few years before we get to a point where we say we have locally adapted varieties,” she said.

    However, this is not to say varieties developed elsewhere can’t do well in Zimbabwe, “but that’s where the research comes in, where you’re actually evaluating varieties coming from elsewhere and you see whether they actually work or not.”

    Speaking while commissioning a usd27 million medicinal cannabis project by Swiss Bioceuticals in May 2022, Zimbabwean President Emmerson Mnangagwa expressed frustration over the slow investment by licensees.

    “It is disappointing that since 2018, only 15 out of 57 entities issued with cannabis licenses are operational,” he said. “Such licenses should not be held for speculative purposes, and those not using them risk government invoking the ‘use it or lose it’ principle.”

    Former Tobacco Industry and Marketing Board chairperson Monica Chinamasa said farmers are still waiting for the ongoing research on varieties that are suitable for the local climate.

    “We are still waiting for the TRB to guide us on this matter,” she said.

    The EU requires GMP and good agricultural collection practices certificates to be in place before a cannabis producer can venture into that business. The financial implications for applying for the certification are huge for some Zimbabwean investors, said Munyaradzi Shamhudzarir of Voedsel Cannabis, one of the few Zimbabwe-owned companies to have planted cannabis.

    “The process of getting these certifications is also very long—at least three years before you can complete all the audits and get certification,” he said.

  • Great Expectations

    Great Expectations

    Photos: Cavendish Lloyd

    Cavendish Lloyd has started growing low-nicotine flue-cured tobacco in Zimbabwe for shisha.

    By George Gay

    Although it’s unfashionable to say so, I believe there is something most appealing about some aspects of tobacco and the tobacco business, not least because they are naturally part of the Slow Movement. Indeed, they were part of that movement long before it came into existence in the mid-1980s with the realization that there was something to be gained in taking the time to savor certain things—and something being lost in doing things too quickly.

    For instance, though many welcome efficiencies have been introduced to the leaf tobacco business over the years, it always had about it, and still has, a comfortingly unhurried air. I mean, there is, after all, no point in a farmer, at the start of the growing season, standing over her seedlings and shouting, “ready, steady, grow!” And who in their right mind would want to walk quickly through a tobacco warehouse when he could dawdle and savor the aroma?

    Of course, not all aspects of the tobacco business are slow, nor should they be. There is a lot to be said for introducing the sorts of machinery updates and general processing efficiencies and manufacturing efficiencies covered in another story in this issue (see “The Virtuous Loop,” page 36). But, at the same time, there are other aspects of the business that have contraventions of the tenets of the Slow Movement that are to its detriment. I find it sad, for instance, to see smokers racing through their cigarettes as they stand in the cold outside pubs and offices.

    Low-nicotine Virginia flue-cured tobacco has the propensity to absorb the high levels of molasses and flavors that Shisha manufacturers require.

    Unseen Advantage

    Luckily, however, there is a type of smoking that still lends itself to savoring the moment, which comprises mainly the enjoyment of products such as fine cigars, pipes and shisha. Shisha smoking, especially, tends to be part of a relaxed social occasion, and perhaps that is why its appeal is increasing at a time when that of other combustible tobacco products is not.

    And that increase in appeal is occurring, I suspect, without too many shisha smokers realizing there is an unseen advantage in their choice of product, the tobacco component of which could have been grown in a more environmentally friendly way than that of many other tobaccos. Indeed, I, too, didn’t know of this potential environmental advantage until I corresponded recently on the subject of low-nicotine Virginia flue-cured tobacco (LNFCT) with Koen Monkau, the president of Cavendish Lloyd, and Frank Magama, the head of the Plant Breeding Division of the Tobacco Research Board’s (TRB) Kutsaga Research Station in Harare, Zimbabwe.

    Monkau told me his company was experimenting in Zimbabwe with growing LNFCT for use in shisha products, and I assumed the aim of using such tobacco was to try to wean people off smoking as is being attempted in the U.S. in the case of cigarettes. But Monkau explained that, in general, shisha manufacturers required LNFCT (less than 1 percent nicotine) mainly because of its physical characteristics. This style of leaf was pale, white-yellow and very thin, he said, and it had the propensity to absorb the high levels of molasses and flavors that needed to be added to it.

    But this style of leaf also has a number of advantages when it comes to the environment and the cost of producing it, partly because it is closer grown than is standard flue-cured tobacco and partly because of a major reduction in the need for chemical applications. Magama told me it was expected that LNFCT would have lower costs of production with significant savings being made from reductions in the use of fertilizer and the cutting out altogether of systemic and contact suckercide applications. Labor savings would be made because topping would not be required, something that normally involved making several rounds of a crop. And energy and time savings would be made on curing the resultant thinner and smaller leaves.

    At the time of this writing, Cavendish Lloyd was in the process of grading its first trial crop of LNFCT.

    Growing Trials

    Cavendish Lloyd was established in 2011 by Monkau, who has been involved in tobacco for more than 25 years, and his wife, Jiayu Wang, who is vice president of the company. The company’s largest operation in respect of staff numbers is to be found in Zimbabwe, but it operates in the Far East, the Middle East and Europe as well as in other parts of Africa. Overall, it has about 100 employees. It is active throughout the tobacco chain, from the growing of tobacco to the marketing and distribution of cigarettes, though, currently, it does not directly operate any leaf processing or tobacco manufacturing facilities—or, I should point out, offer Cavendish tobacco. It is the exclusive distributor of KT&G products in Zimbabwe.

    Given the company’s close association with Zimbabwe, and the country’s favorable climatic and soil conditions, it is not surprising that this is where Monkau is currently conducting, in conjunction with Magama’s team, LNFCT growing trials and where he intends to expand into larger scale production during the next season, which will run from later this year into next year. And it is not surprising, either, that Magama shares this enthusiasm for Zimbabwe. He told me in an email exchange that he believed there was a combination of factors that made Zimbabwe a suitable country for growing LNFCT, including its resilient grower base, the presence of supportive merchants, a long tradition of growing the crop, and soils that were inherently low in nitrogen, which allowed growers to have good control of plant nutrition when producing LNFCT.

    Asked whether LNFCT varieties were more or less difficult to grow than traditional varieties, Magama said that both required the same attention to detail and good management, though, in the case of LNFCT, some key agronomic practices had to be modified, owing, for example, to the previously mentioned need for less fertilizer and the absence of topping. He added that there was so far no clear evidence about whether it was better to grow LNFCT in the dry lands or as irrigated crops, but he said it was important to note that excessive irrigation or precipitation limited growth and nicotine accumulation through leaching of nitrogen while excessively dry conditions resulted in high nicotine accumulation. Much of the year-to-year variation in nicotine content in a variety was due to differences in rainfall, with everything else being equal.

    At the time of writing, Cavendish Lloyd was in the process of grading its first trial crop of LNFCT, which was grown during the 2021–2022 season by a farmer operating near Marondera, Mashonaland East, and with the help of the Kutsaga team. But it has ambitions to quickly increase its production of LNFCT in Zimbabwe, and it aims, eventually, to become a major player in LNFCT by expanding production into Zambia, Malawi and South Africa.

    Koen Monkau (left) created Cavendish Lloyd in 2011.

    Exponential Growth

    Monkau believes that central and southern Africa can provide significant volumes of LNFCT at competitive prices. And, importantly, having done his research, he believes there is a ready market for such tobaccos. “Within the tobacco market at large, there are some segments that are in decline or stable and other segments that are growing fast,” he told me in an email exchange. “The shisha market is definitely in the last category, with even exponential growth expected in the next few years.”

    Given such opportunities come to fruition, it seems likely that other players will be attracted to growing LNFCT in Zimbabwe, a fact Monkau hinted at when he made the point that establishing an LNFCT production industry in Zimbabwe would be an important step in helping to expand and diversify the country’s tobacco client portfolio.

    Currently, no other companies are growing low-nicotine varieties in Zimbabwe or taking part in production trials. However, it seems that interest is growing. Magama told me the TRB had been involved with low-nicotine trials for the past five years, working with many merchants with different objectives and end-use applications. And the board had been selected, he said, to be part of a three-year global study on low-nicotine tobacco being coordinated by a taskforce of the Cooperation Centre for Scientific Research Relative to Tobacco.

    The plant breeding division of the TRB plays a vital role in low-nicotine trials, conducting research and making available where appropriate the results of that research. The division also makes recommendations when called upon to do so by the Tobacco Industry and Marketing Board (TIMB) and other stakeholders. Again, such cooperation is vital because the TIMB is responsible for authorizing the growing in Zimbabwe of any tobacco variety, and it is the TRB that carries out value for cultivation and use studies, and, on the basis of those studies, recommends or not the variety in question.

    Furthermore, two other government departments, the Seed Services Institute and the Plant Quarantine Services Institute, are involved in ensuring only suitable varieties are grown by processing seed permits and ensuring all phytosanitary issues from the country of origin are addressed before seed importation is made.

    It might seem from the above that obtaining permission for experimenting with new varieties would be complex, but, for instance, authorization for the seed used for Cavendish Lloyd’s trials was processed for the company by the TRB.

    The seed in question was obtained from a company based in Europe that has long cooperated with Zimbabwe and is a stable source of supply. But, in any case, Magama said that, depending on the results of the trial, it was possible seed could be sourced elsewhere if it were necessary to address limitations the original seed might have. Further, local breeding efforts could be activated should there be a business case for this nascent tobacco type, he added.

    Finally, without wishing to interrupt the Slow Movement that inevitably controls the scheduling of research and trials, I need to point out that Monkau intends to introduce some allegro con brio into his enterprise. “We plan to grow 1 million kg green from season 2022–2023,” he said. “This might seem ambitious, but we have spent a lot of time on research and are confident we can make it.”

    George Gay is Tobacco Reporter’s European editor, but his territory spans the globe. Based in London, George has covered the tobacco industry since 1982, initially for a U.K.-based publication and since 2004 for Tobacco Reporter. George’s understanding of industry issues, combined with his keen sense of observation and dry wit, have earned him a loyal following among Tobacco Reporter’s readers.
  • The Smoke That Thunders

    The Smoke That Thunders

    A startup cigar manufacturer hopes to move Zimbabwe’s tobacco exports up the value chain.

    By Thulani Mpofu

    When water flowing along Africa’s fourth longest river, the Zambezi, plunges over a cliff to a gorge 108 meters below at a point on Zimbabwe’s western border with Zambia, it produces a roaring sound and a spray of droplets visible from 48 km away.

    From a distance, the immense collection of droplets looks like a pall of white smoke. The Tonga people, among the first inhabitants of western Zimbabwe, call the landform Mosi Oa Tunya, “The Smoke that Thunders” in English. It is now officially known as the Victoria Falls after Scottish missionary and explorer David Livingstone first saw falls on Nov. 16, 1855, and named them in honor of Queen Victoria of Britain. In addition to being Africa’s most famous waterfall and Zimbabwe’s foremost tourist attraction, Victoria Falls is one of the seven natural wonders of the world.

    Zimbabwe’s first cigar maker, which started operating in March 2020, aspires to be what Victoria Falls is to local and global tourism while giving consumers a smoking experience that thunders.

    “The naming of the cigar is not by coincidence,” Mosi Oa Tunya Cigars founder and CEO Shepherd Mafundikwa told Tobacco Reporter. “This will be the smoke that thunders!”

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    Mafundikwa has never smoked but was motivated to consider investing in cigar making after he had a discussion with a friend while in the United States in 2019. They talked about Zimbabwe’s tobacco industry, its contribution to the southern African country’s economy, the level to which it is being beneficiated and prospects for growth. Cigar making featured prominently in their discussion. Mafundikwa had lived and worked in the U.S. for 15 years. Returning to his homeland, Zimbabwe, he and his friend Loy Veal started translating the casual conversation they had had into practice. Harare, Zimbabwe’s capital, was the natural choice for the setting up of the factory because the city is the center for tobacco trade in the country and is surrounded by four tobacco growing provinces.

    Mafundikwa also travelled to Cuba and the Dominican Republic to learn more about cigar making as well as to recruit staff skilled in cigar rolling. He convinced several cigar rollers to come over from Cuba to help him launch the business, but after some time, most of them opted to return home. However, a veteran cigar roller from the Dominican Republic, Elias Lopez, stayed on and became the head of training. He has, since May, been training an all-female workforce of eight.

    The Mosi Oa Tunya team. Elias Lopez is the fifth person from the left and Shepherd Mafundikwa is the sixth. (Photos: Mosi Oa Tunyaosi)

    Lopez, who is also a cigar smoker, has been rolling them for 30 years in the Dominican Republic, Costa Rica, Nicaragua and Panama for companies such as Arturo Fuente, Davidoff and other legends. Prominent American film actors and producers Sylvester Stallone and Chuck Norris have smoked some of the cigars he has rolled during his time in the Americas, Lopez claims.

    “When I agreed to come to Zimbabwe, I didn’t know what to expect,” Lopez said.

    “I must say, I have been pleasantly surprised by the quality of the tobacco, the warmness of the people and the pace at which the students have grasped the cigar rolling skills. I’m proud to be associated with the first cigar making factory in Zimbabwe, and I look forward to being part of the growth this company will definitely experience. The world will soon know and love the Mosi Oa Tunya cigar brand.”

    Zimbabwe is Africa’s leading tobacco growing nation and the sixth largest internationally. The three main types of tobacco grown in the country are Virginia flue-cured, burley and Oriental. Virginia accounts for over 95 percent of the leaf outputs, according to the Tobacco Industry and Marketing Board (TIMB).

    Burley, which Mafundikwa says his company rolls into cigars, contributes between 2 percent and 3 percent of total yearly tobacco output in the country.     

    “Ninety-five percent of our cigar input is locally grown burley,” he said.

    “The wrapper is imported. We are working with local experts to grow the wrapper, and hopefully we will soon have a 100 percent Zimbabwean cigar.”

    I have been pleasantly surprised by the quality of the tobacco, the warmness of the people and the pace at which the students have grasped the cigar rolling skills.

    Elias Lopez, veteran cigar roller

    Goodson Khudu, a research and extension officer at the Tobacco Research Board, said burley is grown in Burma Valley in eastern Manicaland Province near Zimbabwe’s eastern border with Mozambique.

    “That area has the right climatic conditions for the crop,” said Khudu.

    “We have had some German interest in contracting local farmers to grow burley there, and it has been very successful. However, output has been low in recent years, suggesting that the company (Mosi Oa Tunya Cigars) might want to consider promoting its growing in a bigger way so that local production meets all their requirements.”

    The German tobacco firm Von Eicken has been supporting farmers in Burma Valley to grow cubra. In 2016, 11 tons were produced under the Von Eicken initiative. The volume expanded to 20 tons in 2017 and 24.5 tons in 2018.

    Mosi Oa Tunya Cigars recognizes that a large proportion of locally grown tobacco is exported unprocessed, a weakness that is shared by other countries in Africa. The firm produces three blends—light, mild and strong. The light flavor is for beginners and is available in mini cigars.

    “Our staff is still undergoing training, and at optimum production we will be producing 1,500 cigars a day,” Mafundikwa said.

    “We want to scale up production, but the final figures will depend on market demand. Surprisingly, there is a very vibrant cigar smoking culture which we were unaware of. At the moment, all our output is being locally consumed, and there is potential to grow the market as more people become aware of our product.”

    He is happy to be contributing to local tobacco beneficiation in a country that exports up to 90 percent of its leaf raw.

    “This is not peculiar to Zimbabwe,” said Mafundikwa. “It’s a continental problem where countries find it easy to export raw materials. In addition, finances also hinder players getting into manufacturing. We at Mosi Oa Tunya are playing our part in value addition. Governments have to come up with policies and support to start manufacturing entities.”

    Mosi Oa Tunya is confident the quality of its cigars is comparable to that of any brand anywhere.

    The cigar manufacturing industry in southern Africa is small, with reports that there are only two companies in the region that are in the business—Zimbabwe’s Mosi Oa Tunya Cigars and Bongani Cigars in neighboring Mozambique. The latter, which considers itself Africa’s first in this luxury market, hand rolls 10,000 cigars every month with locally grown tobacco and wrappers imported from Cameroon across the continent in West Africa. It was founded in 2016 and, like its Zimbabwean counterpart, relied on a maestro from the Dominican Republic to train Mozambican rollers. It sells locally and exports to South Africa, Kenya and Nigeria, among other countries.

    Mafundikwa is aware that breaking the stranglehold of legends in the elite cigar market will not be easy for his greenhorn. However, his company has already had expressions of interest from Vietnam, Romania, Dubai and the U.S.

    “We are making an African cigar, and we believe the quality is comparable to any brand anywhere given the legendary status of Zimbabwean tobacco. The lure of a new exotic and authentic African product will be our trump card, and we will thrive on competition,” he said.

    Mosi Oa Tunya Cigars has been received well by locals who are excited that at last their country has an exotic product to match their nation’s lofty standing as Africa’s biggest producer and one of the world’s top six growers.

    TIMB chief executive officer Andrew Matibiri said the government always encouraged greater investment in tobacco beneficiation, but the response has been slow. There are about four cigarette manufacturers in the country, with British American Tobacco dominating. The entry of Mosi Oa Tunya into the market, he said, is a welcome addition.

    “It is clear that, yes, we are the dominant growing nation on the continent and among the top six globally, but that dominance has not been matched by corresponding investment in adding value to tobacco,” Matibiri said.

    “I am talking here about the flue-cured leaf, which is more than 90 percent of the national output. But like Oriental and others, we are exporting them in raw form. Therefore, we welcome Mosi Oa Tunya Cigars in the context of the national effort to boost value addition and hope that, with time, they will get all their requirements locally. We are excited that they have joined that niche market and wish them the best.”