Art of cigar making

After harvesting the tobacco, the leaves arrive at the factories for curing and processing. At the plant the leaves are sorted and separated by their grades, filler, binder or wrappers. After the leaves are sorted, they are blended with current and past harvest leaves, then the leaves are stacked in piles one on top of each other. At this time, fermentation begins. During fermentation leaves are cured, moistened and on occasions also liquored.

Long Filler Cigars

After 4 years of aging the leaves are ready to be rolled. The master roller pre-selects the number of fillers leaves in accordance with the blend formula in making a particular size, shape and strength of cigar. The selected binder leaves are rolled around the filler leaves [cigar body] forming a bunch. Bunches are then place on a wooden cigar mold. Molds are then fastened and pressure is applied for several hours. The final step is selecting and cutting the wrapper. The wrapper is then rolled around the bunch spirally, and completing with the “tuck” the trim at the burning end to length. At this point the cigars are ready to be lined in a cellophane plastic and immediately packed in a cedar box and sealed with the authenticity label.

 

 

Lighting Characteristics

The aesthetics of the cigar should have a shiny and clean look, when the cigar is nestled by your hands, it should feel silky, smooth and without bellies.
The Cigar should have a good mouth feel, firm and resilient.
The ash must be white to steel gray color. The burn should be evenly distributed. The draw must not be difficult and the smoke should travel smoothly throughout the length of the cigar.