Our Production Process
Our Cigars are entirely made by us, from the selection of the seed to the delivery to the client.
Step 1: Cultivation of tobaccoTobacco plants are seeded indoors, and transplanted into fields after six to 10 weeks. The plants are carefully pruned so the leaves grow to the necessary size. Plants that produce the outer wrappers of cigars are usually kept covered with cloth to protect them from the sun. The plants take several months to mature in the fields.
Step 2:CuringAfter harvesting, the tobacco leaves must be cured in order to develop their characteristic aroma. The leaves are cured when they have passed from bright green flexible fresh leaves to dried brown or yellowish leaves. Chemically, the naturally occurring chlorophyll in the leaf gradually breaks down and is replaced by carotene. To cure, the harvested plants are strung to narrow strips of wood called laths. The laths are hung from the ceiling of a well-ventilated curing barn. The temperature must be carefully monitored in order to prevent extreme rapid drying.
Step 3:FermentingAfter the leaves are cured, they are sorted by color and size. Small or broken leaves are used for the cigar filler, large leaves for the inner wrapper or binder, and large, fine leaves, usually grown in shade or under cloth, are set aside for the outer wrapper. The leaves are tied into bundles called hands of 10 or 15 leaves each. The hands are packed in boxes or in large casks called hogsheads. The tobacco is kept in the hogshead for a period of from six months to five years. The leaves undergo chemical changes during this period referred to as fermentation. During fermentation, the aroma and taste of the leaf develops. After fermentation, the leaves are manually sorted again by highly trained workers.
Step 4: StrippingThe filler leaves must have their main vein (or stem) removed, or else the cigar will not burn evenly. A worker with a thimble knife fitted to his or her finger clips the vein near the tip and pulls it down. Then the worker stacks the stripped leaves in piles (called books or pads). The stripped leaves are wrapped in bales and stored for further fermentation. The bales may be shipped at this point, if final production resides elsewhere. Just before the leaves are ready for manufacture into cigars, they are steamed to restore lost humidity, and sorted again.
Step 5: Hand rollingThe filler must be packed evenly for the cigar to burn smoothly, and the wrapper should be wound in an even spiral around the cigar. Each worker sits at a small table with a tray of sorted tobacco leaves on it and space to roll out the cigar. First the worker selects from two to six leaves for the filler. These are placed one on top of the other and rolled into a bunch. Then the worker places the bunch on the binder leaf and rolls the binder leaf cylindrically around the filler. The unfinished cigars are placed in an open wooden mold that holds them in shape until they can be wrapped.
Step 6: WrappingWrapping is the most difficult step. The worker takes the partially completed cigar out of the mold and places it on the wrapper leaf. With a special rounded knife called a chaveta, the worker trims off any irregularities from the filler. Then the worker rolls the wrapper leaf around the filler and binder three and a half times, and secures it at the end with a small amount of vegetable paste. The worker cuts a small round piece out of a different wrapper leaf. This is sometimes done by tracing around a coin. This circle is then attached to the end of the cigar with paste. The worker has completed the cigar, though it still must be tested, sorted and packed.
Step 7: Finishing and packingCigars that pass inspection are placed on trays and passed to a banding process. They sort the finished cigars according to minute variations in wrapper color. Cigars with the same wrapper shade are then boxed together.
Visualize Our Care
Sort the gallery below according to the step of the production that you want to see.