Bavuta Beedi was founded in the year 1905 by Shaik Ismail Sahib and is one of the leading beedi manufacturers.
A beedi, called the poor man’s smoke in India, is a thin cigarette or mini-cigar filled with tobacco flake and commonly wrapped in a tendu or Piliostigma racemosum leaf tied with a string or adhesive at one end. The name is derived from the Marwari word beeda—a mixture of betel nuts, herbs, and spices wrapped in a leaf. It is a traditional method of tobacco use throughout South Asia and parts of the Middle East, where beedies are popular and inexpensive. In India, beedi consumption outpaces conventional cigarettes accounting for 48% of all Indian tobacco consumption in 2008.
Due to its relatively low cost (a pack containing 20 pieces of bidis in the USA costs $4.00–$6.00, whereas in India it is $0.08–$0.17), bidis are popular among low and middle-income countries and get imported from India to more than 122 countries worldwide, including the USA.
The Process
A Fascinating story behind the humble beedi
The process of making a beedi is fascinating. It is a 100 percent natural product with even the paper used for ringing and the bag used for packing being made of recycled material.
Procurement of Tendu Leaves
The first step is the procurement of the leaf. The leaf used for making beedis is from tendu trees. The tendu leaves cannot be cultivated and are only available in the forests of Gujarat, Andhra Pradesh, Madhya Pradesh, Jharkhand, and Chattisgarh.
Since the jungles are owned by the Government, they are being auctioned every year. The suppliers who win the tender employ local tribals to pluck the leaves in the Jungle. During this process, they are exposed to extreme dangers from wild animals like lions, tigers and elephants, and even snakes. But their dedication and skill are unmatchable.
Curing of leaves
The leaves are plucked and made into small bundles and transported to the supplier’s godown for curing. The leaves are then dried under the sun. Proper care has to be taken such that every leaf is dried on both sides uniformly. The local weather with dry heat and the absence of wind supports this treatment. When the leaves become brown in color, they are packed in gunny bags.
Grading
The quality control people from Bavuta Beedi will now visit the supplier’s godown to examine the cured leaves to grade and choose the exact size required. Since Bavuta beedis are long, the leaves have to be the widest. So, only the widest leaves are chosen and bought and sent to the production units.
Procurement of tobacco
The tendu leaves are rolled and filled with tobacco. Bavuta beedi has a unique aroma and strong flavor which is due to the high-quality tobacco used in the mixture. Unlike tendu, tobacco is a cultivated crop and hence is graded in the fields by quality control experts. The best of the best quality tobacco is chosen for Bavuta beedis.
Producing the right tobacco mixture
The graded tobacco leaves are brought to the production unit and ground into smaller granules and made into the perfect mixture to achieve consistency in the flavor and aroma. Then the blended mixture is packed in gunny bags and sent to the production centers.
Rolling of beedis
Now that the tendu leaves and the tobacco mixture are in the production centers, it’s time to roll them into beedis. The production in-charge distributes the work of rolling beedis. Work is distributed in lots. A lot consists of thousand beedis.
The tendu leaves and the tobacco mixture are weighed to make 1000 beedis. First, a rectangular stencil is kept over the tendu leaves to cut them into uniform rectangles, the rest of it is thrown away. They are now rolled by the workers. Since the leaves are dry and brittle, they are dipped in water before rolling. The rolls are filled with the tobacco mixture, threaded at the end and the top is closed. The rolled beedis are put on a tray and carried to the factory. Again, a quality check is done to ensure uniform rolling and filling.
Labeling and packing
Then the beedis are sent for individual labeling. A small ring over the rolled beedis. This process is mandatory because the beedis are usually sold in loose. Then the beedis are exposed to heat to reduce the moisture content and to induce crispness. These beedis are then packed into bundles and sent to the dealers for sales.
Health warnings
Beedies deliver more nicotine, carbon monoxide, and tar and carry a greater risk of oral cancers. As with many other types of smoking, beedies increase the risk of certain kinds of cancers, heart disease, and lung disease. They may also be more harmful than other forms of tobacco consumption.
Mfrs. Shaik Ismail & Son
#6, Ramanuja Iyer Street,
Washermenpet,
Chennai – 600 021.
Tamilnadu, India
+91 9840075250
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