Premium Cigars are among the few items that truly are “all natural”. There is no chemical treating, they are free of dyes, and no ripening accelerants are used. Those sweet and spicy flavors occur naturally in the tobacco leaves. Premium Cigar Manufacturers let nature take it’s course to produce the tobacco that will be expertly handled and rolled into a fine cigar. However, as we all know, Mother Nature can throw some curve balls. The master blender must be able to adjust and work effectively with crop variations. Each cigar maker will strive to produce a consistent product with the possibility of slight fluctuations created by weather.
Curious about what it takes before you are able to sit back and enjoy that premium cigar? On recent trips to renowned cigar facilities, we saw the entire production first hand. From start to finish, the components of a cigar will involve well over 200 pairs of hands throughout the process in order to deliver this exceptional handmade product to your humidor. Beginning with the planting of the seeds, to having the leaves harvested and hung in the curing barn, and then piled up for fermentation, each worker skillfully handles the tobacco.
The piles are separated onto drying racks, are then repacked, and are stored for aging. The aged tobacco is unpacked after a few years, rehydrated and separated by color.
The outer leaves used for the wrapper go through a de-stemming process and the filler leaves will have part of the stem removed. The proper proportions of the tobacco are distributed to the rollers where they will bunch and roll each cigar by hand according to the cigarmaker’s blend. The art of rolling the perfect cigar is one that takes years to master.
The finished product is sorted for color consistency and sent back to the aging room. Finally, the cigars are banded, boxed, and sent out.
Along the way, the cigars have also gone through numerous quality control steps, all completed by hand. This entire journey has been a hands-on process with dozens and dozens of skilled labor taking the proper care to ensure a consistent and satisfying smoke. So the next time you enjoy a cigar among friends, remember all the expertise that went into your hand-rolled premium cigar, from start to finish.