HANDMADE CIGARS
 To make handmade cigars, the
bales of cigar tobacco are brought into the rolling factory
and placed in a temperature and humidity controlled
area.
The tobacco for cigars is unpacked on an as needed
basis and classified once again by the color, size and
texture of the fully fermented and aged leaf. After
carefully selecting the cured leaves, they are transferred
and organized in the blending room based on the cigars to be made and their blend. The handmade cigars process requires precision.
The Master Cuban Cigars blender prepares the tobacco leaves
for the cigar Roller and Master Roller teams. The teams work together as a pair to hand make the cigars. The
Blender normally mixes enough tobacco for the daily
production of the handmade premium cigars by the Roller and Master Roller pair.
 The
Rollers are highly trained and only reach the Master
level after many years of on-the-job training. First
the Roller “bunches” the tobacco leaves
and forms the cigars. It is done by taking a measured
handful of leaves for the filler and then forming it into
the desired shape. Then they wrap a binder leaf around
the filler tobaccos to hold them together. The partially
finished cigars are pressed in a wooden mold. The press
is turned by hand until the Roller
feels that there is enough pressure on the tobacco leaves
to properly form the cigars into perfect, predetermined
shapes. After the press is released, each cigar is removed
from the mold by hand and passed on to the Master Roller.
 The
Master Roller, who is the most experienced member of
the pair, carefully finishes the forming of the cigar
and delicately puts on the wrapper leaf. Both hands are used in this process, a chaveta (hand cutter for tobacco leaves), and an all natural tree sap glue.
The Master Roller puts on the head of the cigar and
looks it over for any possible flaw or imperfection. After adding
the finishing touches and details, it is now
ready for the aging process, which requires patience and time.
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