Not every manufacturer has its own farm or factory. Some farmers sell crops to cigar makers and some crops have fermentation involved. We buy our tobacco from suppliers and restart the fermentation process again at our factory to take out humidity & control temperature. Leaves are tied into bundles of 10 to 15 leaves during the fermentation process. It can take 6 months to 5 years to achieve desired outcomes. The purpose of fermentation is to develop the aroma and flavor of the leaves. Once this process is over, the leaves are sorted by hand again.

Our rollers work in pairs.  First, they choose the number of filler leaves needed for a particular cigar blend. Filler leaves come in different sizes, shapes, colors, and even can be from different countries. From here, they are bunched together by hand so the roller can feel the balance and weight of the leaves. You don’t want to put anything in the filler that affects the draw. Once this is done, the roller wraps the binder leaf around the filler in a cylindrical motion, either by hand. The binder is the finishing touch in a cigar’s recipe. The wrapper is then used to keep the cigar uniform. Wrapping the cigar is probably the hardest part, requiring firm yet delicate patience so it does not break. Strong eyesight is needed to ensure the wrapping is done to visual perfection. A chaveta is then used to cut the cigar. The ends of the cigar are cut so a cap can be added. This is the circular piece of tobacco that prepares the cigar for being packed. Some of the finest cigars have a triple-cap, swallowing the whole wrapper leaf and appearing like three seams.

From the aging room, the cigar enters quality control.  Cigars are examined by color, for construction consistency and presentation before moving on. If it passes, a band is applied by hand, and it is moved into a box. We utilize some form of inner packaging for extra safety. These are now ready for consumers to smoke.