Cigars are well-known for being some of the most expensive and luxurious premium items on the market. The price tag and the fame are both given by the long and tedious making process. There are many steps from the moment the tobacco seed is planted until the cigar is lighted up. We are presenting you this amazing process in order to better understand the long road every cigar has to make before reaching your humidor.
In Cuba especially, there are many tobacco farms that are partially owned by the locals and partially by the state. All these farms have a very long history and they have a vast experience in growing the tobacco farm. Each farm can have a specific type of tobacco or several types at once that are going to be used in the process of making a cigar.
After around three months of growth, the tobacco leaves are harvested and they are hung in special chambers in order to dry. This process takes another three months as well. The conditions from these chambers are very special and the tobacco that is pesticide-free receives special attention because the farmers have to take the insects off the plants by hand.
This is a crucial step in cigar making. The fillers, the binders, and the wrappers are sorted based on strength, color, texture, size, and resiliency in order to make up the batches for the next cigars. This particular step has many smaller processes that have as an aim to prepare these components. This particular step of sorting can take up to several years because these components have to be perfect the moment they reach the hand-roller.
The batches used for certain cigars can be made up of tobacco from a single farm or from a multitude of batches. The diversity of tobacco gives the unique taste of the cigar, just like in the case of Hoyo de Monterrey Epicure Especial.
In this step, the tobacco leaves are gathered together in a special container called “Spanish Book Filler” and then taken out and mounted in a cylinder that will go under a press. This strep has the role to give a certain density to the cigar. The cigars are constantly turned over in this press in order to make sure that they don’t get creased. This is a long process that can take several days. This long time is used in order to make sure that all the cigars have the same density and shape.
This is one of the last active steps in the process of making a cigar. The hand-rollers take the specially selected wrapper leaves and they carefully cover the binder. The wrapper leaf has a certain elasticity that will allow the hand-roller to apply it on the cigar. This is the most delicate step in the process of making a cigar and the step that gives the smooth finish to the cigar. An example of a beautifully crafted cigar that features all the premium requirements of a true Cuban is Bolivar Libertador.
This is the final part of the cigar’s road before being stored. All the cigars are carefully inspected for flaws and they are given their cigar bands. They are then weighted in batches of 50. If the weight does not correspond certain standards it means that the hand-rolled bound them too tight or too loose. The cigars that do not meet the requirements of the manufacturer will never reach the market. Cuba is notorious for the strict regulations in terms of quality of the cigars.
If the cigars passed the inspection, they are going to be stored in special rooms in order to age beautifully. The storage rooms have special chambers for different types of cigars. This way all the cigars that are stored in a certain room will have the same taste and aroma. There are some manufacturers that use these rooms in order to combine the flavors of a multitude of cigars in a single one, making a staple taste and a unique batch in this way.