From brown leaves to cigars
In
the casa de tabaco, the dried leaves are taken down from the drying lines,
stacked in bundles and left to undergo primary fermentation.
Later, the leaves are taken out the casa de tabaco and sorted into wrappers,
binders and fillers. The leaves are also grouped according to their colour
and size.
The selected and classified leaves are tied into tercios and left to age.
During the aging process that may last between a few weeks and
a few years, the leaves (in function to their composition) assume a more
golden brown colouration.
At
the end of the aging period, the mid vein of the leaves that are destined
to serve as binders and fillers are removed in the despalillo
Between the end of drying and rolling, the leaves are, however, subjected to different phases of fermentation. The number of fermentation phases, which depends on the intended role of the leaves in the cigar-making process, varies between 3 and 5.
Fermentation is a natural process that leads to the degradation of irritating substances that are contained in the tobacco leaves. It strengthens the aroma in the leaves as well as improves the combustibility of the leaves and bestows on them the most desired colours characteristic of the class of tobacco.
The fermentation stages are a very important phase in the production
of cigars. If fermentation is not properly done, the cigar will be powdery,
piquant and bitter. The
last phase in the production of a cigar starts with the rolling of the
leaves. As the mid vein of the wrapper leaves is removed, the binder and
filler leaves are simultaneously assembled together to form a bunche.
Already,
the bunche corresponds to a well precise modular length and diameter.
The number of fillers used depends of the desired diameter of the cigar.
The cigar assumes its definite shape after passing through the press. 
The assemblage of filler, binder and wrapper leaves is termed liga. Elaborated
during the manufacturing process, it is always a perfectly guarded secret
because it determines the aromatic characteristics of the cigars produced,
as well as ensures the patronage of cigar smokers to its brand.
The ultimate
phase consists of rolling the wrapper leaf around the bunch that had been
previously rolled and pressed.
The cigar is then fully manufactured.
