A Cigar is a natural product and the quality of a cigar is directly linked with the type and quality of tobacco used in its production, just as the wine depends on the type and quality of grapes used for the brewing.
The fields for tobacco are flat so that the seeds don’t flow away with the water stream. After planting the seed, they are covered with cloth or straw to protect them from the direct light of the sun. This covering is gradually removed as they begin to germinate, and after around 35 days the fields are sprayed with pesticides, they are then transplanted in to tobacco fields usually in the second half of October. The fields are irrigated from below and the leaves are watered both by rain and the morning dew.
The tobacco plant is mainly considered as a three parts plant: the top of the plant is called corona, the middle, and the bottom. As the leaves grow, buds appear at the top. These have to be removed by hand to prevent the plants from stunting leaf and growth. The quality of wrapper leaf is very important for any cigar. A special type of plant called Corojos, specifically used to provide wrapper leaves for the very best cigars. These plants are always grown under gauze sheets held up by tall wooden poles, which protects them from becoming too thick in a protective response to sunlight. Another technique, called tapado can also be used to cover the plants to helps them remain smooth.
During the harvest, leaves are removed by hand using a single movement. The selected leaves for wrappers are put in bundles of five called manojo, or hand. The leaves are picked in six phases:
libra de pie (at the base) uno y medio (one-and-a-half) centro ligero (light center) centro fino (thin center) centro gordo (thick center) corona (crown)
The libra de pie section cannot be used for wrappers. A gap of one week is given between each phase. The finest leaves are found in the middle of the plant; the top leaves (corona) are usually too oily to be used for wrappers so they are only used for domestic consumption, and are often used as binder leaves. Each plant is visited for an average of 170 times and the whole cycle from transplanted seedlings to the end of harvesting takes some 120 days.
The wrapper leaves grown under cover are classified by color:
ligero (light)
seco (dry)
viso (glossy)
amarillo (yellow)
medio tiempo (half texture)
quebrado (broken)
The plants, which are grown direct sun, are divided into volado, seco, ligero, and medio tiempo. The leaves from the top of the plant have a very strong flavor, the seco from the middle are much lighter, and the volado leaves from the bottom are used to add bulk and for their burning qualities. To make a good quality cigar, all the various types are blended together, along with a suitable wrapper leaf, in a special proportions to give cigar a mild, medium, or full flavor. It also ensures that the cigar will burn well. Large, average, small size are classified and by physical condition. Unhealthy or broken leaves are used for cigarettes or machine-made cigars. If all the leaves are good, each wrapper plant can wrap 32 cigars. The condition and quality of the wrapper leaf is important for the attractive appearance of a cigar, as well as for the aroma and taste.
The bundles of leaves are then taken to a shelter. The shelter faces west so that the sun heats one end in the morning and the other in the late after-noon. The temperature and humidity under the shelter is carefully controlled, by opening and closing the doors at both ends to take account of changes of temperature or rainfall. The leaves are left to dry for between 45 and 60 days, depending on the weather. During this time, the green chlorophyll in the leaves turns to brown carotene, giving them their characteristic color.
Then these are brought to fermentation houses and placed in piles about three feet high, covered with jute. Enough moisture remains in the leaves to start the fermentation. Heat develops, but the temperature must be watched carefully so that it does not exceed 92 degrees F during the 35 to 40 days that the piles are left intact. The leaves assume a uniform color.
These leaves are then sorted and stripped. Each leaf is carefully examined and graded. Broken leaves are set aside, to be used for cigarettes.
The leaves then return to the fermentation area. The second fermentation begins within the damp leaves. The temperature inside must not exceed 110 degrees F for around 60 days. Because of the fermentation process, cigar tobacco is much lower in acidity, tar, and nicotine than cigarette tobacco, making it much more appetizing.
It is now time for the leaves to be sent to the factories or warehouses for further production.
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