Handmade Cigars
The manufacturing of cigars is centuries old and has bee perfected tremendously in the last fifty years. It is a simple process but requires perfect precision to manufacture a quality cigar.
First the tobacco leaves are grown and harvested. Once harvested, they then undergo a process called curing for about a month. During curing the leaves are aged with a combination of shade and heat to rid the tobacco of water and sugar. Without this first step in the process, the leaves would simply rot. Based on the climate, temperature and type of tobacco this process can greatly differ in varies places around the world.
After the curing stage the leaves are then fermented under very specific conditions. The purpose of this process is to aid the leaves in dying slowing so they don’t decay or rot. It is this part of the process that produces the aroma, color and flavor of the cigar. The fermentation process is very sensitive and crucial to producing a rich and flavorful cigar.
Once the leaves are properly fermented the manufacturer will inspect the tobacco until it is matured to the proper requirements. Once it is approved to be made into a cigar, it is still inspected to decide whether it should be the filler or wrapper of the cigar. Leaves rich in color and texture are reserved for the wrapper and those not as aesthetically pleasing will be used as the filler.
The tobacco is then hand rolled, if it is a quality cigar, shipped to the retailer and stored in a humidor at 70 degrees with a relative humidity of 70%. The cigars are then laid on display and wait for a buyer to enjoy!