Cigar Manufacturer Process

Cultivation of tobacco

Tobacco plants are seeded indoors, and transplanted into fields after six to 10 weeks. The plants are carefully pruned so the leaves grow to the necessary size. Plants that produce the outer wrappers of cigars are usually kept covered with cloth to protect them from the sun. The plants take several months to mature in the fields.

Curing

After harvesting, the tobacco leaves must be cured in order to develop their characteristic aroma. The leaves are cured when they have passed from bright green flexible fresh leaves to dried brown or yellowish leaves. Chemically, the naturally occurring chlorophyll in the leaf gradually breaks down and is replaced by carotene. To cure, the harvested plants are strung to narrow strips of wood called laths. The laths are hung from the ceiling of a well-ventilated curing barn. In dry weather, they may cure simply by hanging, a process called air curing. The leaves may also be flue-cured. In this method, the laths are hung in a small barn which is heated from 90-170°F (32.2-77°C). The temperature must be carefully monitored in order to prevent extreme rapid drying. Sawdust or hardwood may also be burned in the curing barn, to aid in drying the leaves and impart an aroma.

Fermenting

After the leaves are cured, they are sorted by color and size. Small or broken leaves are used for the cigar filler, large leaves for the inner wrapper or binder, and large, fine leaves, usually grown in shade or under cloth, are set aside for the outer wrapper. The leaves are tied into bundles called hands of 10 or 15 leaves each. The hands are packed in boxes or in large casks called hogsheads. The tobacco is kept in the hogshead for a period of from six months to five years. The leaves undergo chemical changes during this period referred to as fermentation. During fermentation, the aroma and taste of the leaf develops. Cigar tobacco is usually fermented longer than other tobacco. Fermentation for two to five years is typical for high quality cigars. After fermentation, the leaves are manually sorted again by highly trained workers.

Stripping

The filler leaves must have their main vein (or stem) removed, or else the cigar will not burn evenly. This can be done by hand or machine. Manually, a worker with a thimble knife fitted to his or her finger clips the vein near the tip and pulls it down. Then the worker stacks the stripped leaves in piles (called books or pads). Mechanically, a worker inserts the tobacco leaves into a machine under a grooved, circular knife. By depressing a foot treadle, the worker causes the knife to lower and cut out the vein. The worker can stop the machine with the foot treadle, and stack the stripped leaves.

The stripped leaves are wrapped in bales and stored for further fermentation. The bales may be shipped at this point, if final production resides elsewhere. Just before the leaves are ready for manufacture into cigars, they are steamed to restore lost humidity, and sorted again.

Hand rolling

Fine cigars are rolled by hand. Cigar rolling is skilled work: it may take a year for a roller to become proficient. The filler must be packed evenly for the cigar to burn smoothly, and the wrapper should be wound in an even spiral around the cigar. Hand cigar makers usually work in small factories. Each worker sits at a small table with a tray of sorted tobacco leaves on it and space to roll out the cigar. First the worker selects from two to six leaves for the filler. These are placed one on top of the other and rolled into a bunch. Then the worker places the bunch on the binder leaf and rolls the binder leaf cylindrically around the filler. The unfinished cigars are placed in an open wooden mold that holds them in shape until they can be wrapped.

Wrapping is the most difficult step. The worker takes the partially completed cigar out of the mold and places it on the wrapper leaf. With a special rounded knife called a chaveta, the worker trims off any irregularities from the filler. Then the worker rolls the wrapper leaf around the filler and binder three and a half times, and secures it at the end with a small amount of vegetable paste. The worker cuts a small round piece out of a different wrapper leaf. This is sometimes done by tracing around a coin. This circle is then attached to the end of the cigar with paste. The worker has completed the cigar, though it still must be tested, sorted and packed. 
 
Cigars come in several shapes and sizes. Perfecto refers to a cigar with a pointed head and tapering sides; Panatella is a long, thin, straight cigar; Cheroot is an open-ended cigar, usually made in India or Asia. From the smallest [3.5 in 18.9 cm)] to the largest [7.5 in (19 cm)] cigars are labeled the Half Corona, Tres Petit Corona, Petit Corona, Corona, Corona Grande, Lonsdale, and Double Corona.

Cigars may be made by hand in teams. Some workers may make the bunch and wrap it in the binder, and then the more delicate finishing work of rolling the wrapper is left to more skilled workers.

Humidor Tips

HUMIDOR TIPS AND INFORMATION

With proper care and attention, your humidor will give you many years of service. To help maintain your investment, follow these tips.

STORAGE

Place your humidor on a flat level surface. This will guard against accidental damage from being knocked over.
Never place your humidor near a heating vent or in direct sunlight. The sun could fade the finish of the wood and raise the temperature inside the humidor.
Avoid placing objects on top of your humidor.

CLEANING

Always use a soft cloth when cleaning your humidor.
We recommend that you use a good furniture polish to protect your humidors outer finish.
Regular dustings will help keep your humidor looking as good as new.
IMPORTANT NOTES

Do not wipe the interior of your humidor with water or any other liquid as it may damage the cedar lining.
Place your humidor in a cool dry place. Cigars should be stored at around 70 degrees.
Avoid any unneccesary opening of your humidor lid. This will allow humidity to escape.
Avoid storing foreign objects such as lighters, cutters, etc. inside the cigar storage portion of your humidor.

BREAKING IN (SEASONING) YOUR HUMIDOR

The wood inside your humidor is high quality Spanish cedar that is kiln dried. This process guards against sapping, splitting, and warping. In order for it to perform at its best the wood must re absorb moisture. Please follow these directions to properly season your humidors. 
Place a shot glass filled with distilled water in the bottom of your humidor.
Charge the humidifier (see humidifier section below) and place it inside your humidor.
Place the calibrated hygrometer inside the humidor.
Close the lid.
Check the humidity reading on your hygrometer daily. When it reaches 68 - 72% range, the wood has been properly stabilized. This is considered the ideal range for proper cigar storage.

NOTE - Do not saturate the interior of your humidor with water. This may cause damage.

CHARGING AND FILLING YOUR HUMIDIFIER

Remove the humidifier(s) from the humidor.
Fill your humidifier with a good quality Propylene Glycol Solution. We recommend Madelaine Brand "Use Every Time" PG Solution.
Do not overfill the humidifier. You want it wet, not soaking.
Wipe any excess liquid from the front of the humidifier with a clean dry cloth.
Re-attach humidifier back into humidor.
HOW TO CALIBRATE YOUR HYGROMETER

Most humidors come equipped with hygrometers. Before use we recommend that you calibrate its accuracy. Follow these simple steps to insure that the analog hygrometer included with your humidor is working properly. (Digital hygrometers do not require calibrating)
Place a teaspoon of table salt in a plastic dish and add just enough water to make it damp.
Place the dish in a zip lock plastic bag and place hygrometer next to it. Take care not to spill any salt water onto your hygrometer.
Seal the plastic bag with some air trapped inside, and allow it to sit for at least 6 hours.
Ater the time has elapsed, the hygrometer shoud read 75% humidity. Some hygrometers have a small screw on the back that will allow you to adjust the reading if it is incorrect. If yours does not, make a note of the deviation.

HYGROMETER PLACEMENT

To insure an accurate humidity reading, do not place your hygrometer next to the humidifier. Keep it in an area where air will circulate around it. Mounting your hygrometer on the lid interior or on a tray inside the humidor is recommended.

Cigar Smoking 101...

Selecting A Cigar
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Today there are a larger variety of cigars than ever before. Selecting a cigar is the first and most important part of the experience. First, decide the level of body you are comfortable with. Strength for the sake of strength is overrated. A full body cigar should be felt in your stomach rather than in your throat or on your palate. The thickness of the wrapper leaf is a good measure of the body of a cigar. A thicker wrapper will generally deliver fuller body as it has a greater amount of oils. The thickness of the wrapper can be gauged by looking at the area where the wrapper overlaps in a cigar. Next, you will need to decide on a size. This should be determined by the amount of time you have available for smoking as well as the amount of smoke you enjoy. The large ring gauges (52-60) deliver large amounts of smoke and flavor. The medium ring gauges (43-50) are ideal for most blends as they are a good balance of smoke and flavor. 

Storing Cigars
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Proper storage is fundamental. Cigars should be stored without cellophane in a humidor which has an adequate seal. It should be checked often to insure proper conditions (70% humidity). Contrary to popular belief, cigars should not be stored in a refrigerator or in a freezer. Either of these will affect the natural oils found in the leaf. Always take into consideration that air conditioning as well as heating will affect the humidity in your humidor. 

Aging
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Aging is a complex process which requires special attention. While all cigars show some degree of maturity from additional aging, not all cigars age well. A common misconception is that a cigar which was rolled with “new” tobacco will lose its bite and harshness through humidor aging. No amount of humidor aging will mellow “new” or un-cured tobacco. 

“The best cigars for aging are those which were well balanced and enjoyable to being with.” 

Proper aging requires a designated humidor which will not be used for daily use. It should have a capacity that exceeds the amount of cigars to be aged by at least 20%. Cigars should be placed in the humidor without cellophane. Allow for space for the head and foot of the cigars evenly. The humidity source should be one that can exceed 70% humidity. Aging cigars should be kept at 70%-79% humidity depending on the thickness of the wrapper. Thicker wrappers require higher levels of humidity. Once desired age is achieved a cigar should be brought to 70% before smoking.

Recommended Aging
High Primes (Thicker Wrappers) Maduro/Habano/Corojo/Habano 2000/Criollo/Sumatra/3-7 years 

2-3 Primes (Medium Wrappers) Low Primes/Ecuador Connecticut/2-5 years 

1st Cut (Thinner Wrappers) USA Connecticut/Cameroon/1-4 years

Cutting A Cigar
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Several methods exist for cutting a cigar. It is generally a matter of personal preference. A scissor or guillotine cut usually provides a better draw. When cutting a cigar special attention should be given not to cut below the “cap”. The cap holds the wrapper in place, cutting below it can cause the wrapper to loosen. The crown of the cigar should be cut (test the draw then cut accordingly). 

Lighting A Cigar
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When conditions allow, a cigar match is the preferred lighting source. However, the recent advances in the way of precision torch lighters have almost eclipsed the match. Either method is appropriate. Lighting a cigar properly requires one important note: Only apply fire to the exposed leaves at the end of the cigar. Do not burn the edges of the wrapper at the foot of the cigar. Roll the cigar and distribute the fire evenly. Once the exposed tobacco is evenly red your cigar is lit. 

Smoking A Cigar
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How one smokes a cigar will affect the overall flavor. Puffing quickly and often will raise the temperature of the cigar and result in a spicier smoke. One should take slow deliberate draws on the cigar, slowly releasing the smoke and enjoying the taste on your palate. Cigars should not be inhaled. The experience happens at the palate.