TOBACCO WHOLESALE AGING
 Aging Tobacco. The
fermented tobacco leaves are individually placed on burlap and each layer
is stacked over another. They are moved to a different section of the
curing house where the tobacco for the cigars ages for years. The temperature and humidity
are regulated by nature and by the opening and closing of windows and
vents in the aging room. Normally, the tobacco is aged for two to three
years before it is manipulated again. This process mellows the tobacco’s
components and transforms it into smooth and flavorful smoking cigars.
After it has been determined that the tobacco leaves are properly aged
by Tabacalera Esteli’s Cigar Master Maker, Don Kiki, the tobacco is taken
to a select area where each leaf is hand sorted.
The sorting is done by professionals that
are knowledgeable about cigars and in categorizing each leaf by color, size, texture and
other qualities.
The tobacco leaves are then stemmed by hand, one by one. This is a very
labor intensive task and requires precision actions as any error could
damage the perfect leaf.
The stem is discarded and the wholesale tobacco
leaves are placed in stacks for a second fermentation. This time the fermentation
process is at higher temperatures. Based on the classification of the
tobacco leaves, the fermentation period ranges between 45 to 60 days.
Impurities are once again eliminated and the tobacco leaves ready to be aged again.
This time the stemmed leaves are placed in open cedar boxes and left in
the curing house’s aging room to breath. They can be kept there
for up to two years. Making the worlds best cigars requires patience.
When
it is determined that they are at their prime by Master Cigar Maker Don Kiki,
they are packed into bales and aged further until they are needed for
rolling cigars.
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