A cigar does not just come into the store before this the cigar is being taken a long way. During this process must happen a lot and at the right time . The right moment is dependent on the circumstances such as the nature gives them , the knowledge of the grower is of great importance .
The tobacco seed
It starts first with the land, which piece of land is chosen to let the tobacco plant grow. How fertile is the soil and how much can shine the sun. Whether in Indonesia , Brazil , Nicaragua or Central America ,but if the soil is rich in minerals and loamy . The selected tobacco seed is of great importance because it says something about : taste, aroma 's , the size , the color and structure of the plant. Each tobaccoseed has its own ideal suitable soil, why and how this works is a closely guarded secret of nature.
The purpose of the plant
From the beginning of the cultivation , there will be a choice for the purpose of the plant , this can be the filler , binder or wrapper. The small plants are often grown in a protected environment , in order to protect the tender plants against pests , to extreme weather conditions or other bad influences. After approximately 40 days, the plant 10 cm high, and is turned off , the plant in the field. On the plantationthe plants are well cared for every day by watering and weeding.
The process of planting until harvesting takes about 6 months. The exact time required depends on the circumstances of the plant (temperature, humidity etc.) . There will never be harvested when it rains , the time of harvest is very important. It should not be too hot for the plants, but also not too early to weather the plants are still wet with dew. The tobacco leaves are picked by hand, page by page .
First, the lower leaves are plucked than the middle and later the top , the big advantage is that the leaves are picked last , most feeding the plant has received (there is usually a number of days between picking the bottom up to the upper layer of the plant).
The harvested green leaves are then transported to the drying area , these are often large barns. Here the leaves are bundled and hung to dry.
The tobacco leaves will slowly change color during the drying process , in this respect is the temperature and humidity of interest. Of course the humidity of the leaves are changing drastically during this process , it drops from 90 to 25 %. During this process, the leaves by hand to be removed separately in order to avoid that they stick together to sit during the drying, the drying of the leaves takes about 40 days.
Store and dry
Store and dry is actually not the correct name, fermentation is so. But this word also deserves some explanation , with fermentation they mean the process in which the tobacco leaves are stored in a warm room where the fermentation takes place ( a kind of fermentation ) . During this part the leaves change in tobacco. During this process, sugar , nicotine and other substances vaporise decomposed , various flavorings and the tobacco gets its natural aroma. This is the natural process without artificial additives. This is part of great importance in the way of tobacco seed to cigar.
After all previous steps it's time to sort the tobacco leaves. The first choice made concerning: the filler, binder and wrapper. Thereafter, the further selection can find place on the basis of color, quality , strength, thickness etc.
Since the tobacco leaf is a real natural product as you can read in the previous steps with the tobacco leaves all have their own color. The size of the blade also determines what type of cigar leaf is appropriate. After this part of the wondrous journey bales of tobacco is in storage to make them ripen .
The making of the cigar
In each country they have their own tradition in making the cigar. Here there is also a difference between the long and short fillers fillers. The cigars are handmade and one leave rolled then it follows a completely different path as another cigar.
For cigars are not made entirely by hand, there is another route, be first wrappers from the leaves cut out with a sort of "template". The saved are on a roll and sent to the factory where the cigars are made further stamped covers. During this process, of course, the quality of the cigar checked several time.
Saving the cigars
Imagine that the cigar has passed all inspections and the product is fully approved then the cigars are stored. Then, the cigars are stored in a damp room, during this storage, the flavor changes for the last time.
Ready for sale
Now that all necessary steps have been completed in order to make a quality cigar that you can buy from us; The cigars can be packed. This varies by product as there are cigars that are sold in bundles, others cigars are usually done in boxes of 25, 50, 100 or 150 pieces so that everything can be shipped. There are also these cigars are cigars that are sold in bulk packed in large boxes and are later placed in smaller packages.