In a medium bowl, whisk together the flour, baking powder, baking soda, ginger, cinnamon, cloves and salt.
In large mixing bowl, with paddle attachment, beat the butter, brown sugar and egg on medium speed until well blended, about 3 minutes. Add the molasses, vanilla extract and orange zest and beat until blended. Gradually add flour mixture 1 cup at a time and mix until just combined.
Divide dough in half and wrap each in plastic wrap. Place in the fridge for at least 2 hours or for up to a day.
Once dough is ready, preheat oven to 375°F. Pull one disc out and let sit at room temperature for 5 minutes. Line cookie sheets with parchment paper. Sprinkle flour on dough and surface and roll out to ¼" thick. Use cookie cutters to cut desired shapes.
Place on baking sheet about 2" apart. Bake 1 sheet at a time for 7-10 minutes. The shorter time gives you softer cookies, while the longer time gives you crispy cookies. I bake mine at 8 ½ minutes for the consistency I like.
Remove from oven and allow cookies to cool on sheet for about 5 minutes before moving to a cooling rack. Allow the cookies to cool completely before decorating.
Royal Icing
In a large bowl using a hand-held mixer or a stand mixer fitted with a whisk attachment, beat all of the icing ingredients together on high speed for 5 minutes until stiff peaks form. Always start with 3 tablespoon of water to be safe, but you'll probably need 4 for right consistency. If it's too thin, add more powdered sugar and if too thick, add more water.
Notes
Don't skip placing the dough in the fridge so it firms up and doesn't spread too much when baked.
Use parchment paper and add flour to rolling pin when rolling out cookie dough so it doesn't stick.
You know cookies are done when edges are firm, but middle is slightly soft.
The longer you cook the gingerbread cookies, the crispier they get.