The tobacco plant has been known to mankind for over 10 centuries. It originated in the Yucatan peninsula of Mexico.On October 28, 1492 when Columbus landed in Bariay, Cuba, the “Tizon”, a primitive form of cigars was first seen by Europeans. The Tizon was introduced to Europe and rapidly became popular, especially among Spaniards and Portuguese.
Two centuries later, the raw material, tobacco, further developed, reached the rest of Europe. From then on it was consumed by kings, nobles and the aristocracy of the continent.
How's the cigar made?
The Long Filler cigar is made up of three parts:
After harvesting, drying, fermentation and classification following are the main stages involved in the preparation of a long filler premium cigar (filler with twisted whole leaves).
Entire leaves are twisted and a sub-wrapper called “capote” (binder) is used to hold the leaves together.
The twisted cigars with the binder are placed in a wooden mold or plastic material in individual spaces for each cigar in order to standardize their size.
The molds are closed and pressed for 30 minutes. They are then opened and cigars are turned to avoid leaving marks. They are next pressed for an additional 30 minutes.
Before opening the mold to remove the cigars, the portion of the cigar that remained out of the mold is cut with a half-moon knife called “chaveta” (tobacco shreds are used in “Short Filler” cigars and cigarillos) .
After cigars are removed, they go through a drying period to eliminate excess humidity prior to the wrapping stage.
The wrapper is prepared, humidified and cut to proceed with the wrapping process. The wrapper is then glued with vegetable glue (cassava glue and cigar ashes).
After wrapping, the tip of the cigar is trimmed with a small guillotine and a piece of the same wrapper is glued to close the end of the cigar and give it its final appearance.
Next the cigars are dried to remove the excess humidity.A rest period follows in pink cedar chambers with controlled temperature and humidity for 30 days.
Final quality control checking is made.Rings are placed.A cellophane cover is placed where applicable.Cigars are placed in boxes.
Boxes are sealed with certificate of origin and warning labels affixed.