The tobacco leaves before becoming stogies must go through three different processes: drying, fermentation and aging. At each of these processes the temperature, the humidity and other things used are considered to be crucial factors. Without these three processes we will never enjoy a good cigar, but only low- quality cigars that will offer our palates the worst memories.
The drying processes can be diverse: sun drying, air drying, dried above a fire and kiln drying. The fastest method for drying the tobacco leaves is through kiln drying. This will not take more than 4 days. On the other hand, the slowest and yet the most effective method is through air drying. However, this will take up to 60 days. Still, this method is assuring the finest flavors of the wrappers leaves.
The tobacco leaves are dried in special buildings where it is maintained a temperature of no more than 29 Celsius degrees, and the humidity is maintained at a level of 75- 80%, but no higher than this.
The fermentation process is the second one applied to the tobacco leaves. This process also occurs in the drying houses, but only the first part of it. There are some factories that subject the tobacco leaves at the process of fermentation for almost 6 times. So, the first part of this process is made in the same place as the drying process because the leaves are “weak”. They are vulnerable and if you transport them they can be easily damaged. Also, if during transportation it is raining, so the humidity will have a high level, the tobacco leaves will be damaged because the fermentation cannot be controlled anymore.
The second part of this process is made into the tobacco houses. In that place, the tobacco leaves will be removed from their posts. After that they will carefully packed into large bales where the air will not be able to enter. There are three factors that can lead to a well- done fermentation or a bad one. They are the humidity, the water and the temperature. For recording and controlling the temperatures from the tobacco houses, and exclusively of the bales where the leaves are left to fermentation there are putted thermometers. This way, it is impossible for the tobacco leaves to get overheated and to even burn.
The process of fermentation ends when the temperature from the bales stops rising. Actually, this is the only way through which someone can notice that this process was completed.
Now, the third process through which the tobacco leaves must go through is the aging. This is the longest process through which the leaves must go through. In the last years, the aging process was of 5 to 6 years, but now it is merely of half a year due to the immense demand of cigars from the market. During this process the tobacco leaves are hold in palm- tree leaves, let to age properly as long as the factories are allowed.